Light emitting diode

ABSTRACT

A microelectronic device is disclosed. The microelectronic device has an outer enclosure enclosing a first gas in a first space, an inner enclosure disposed in the first space of the outer enclosure, at least one elongated elastomeric member disposed in the inner enclosure, and a plurality of lighting elements embedded in the at least one elongated elastomeric member.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a Continuation-in-Part of U.S. Nonprovisonalapplication Ser. No. 17/194,223 filed 6 Mar. 2021; which is aContinuation-in-Part of U.S. Nonprovisonal application Ser. No.16/657,297 filed 18 Oct. 2019; which is a Continuation of U.S.Nonprovisonal application Ser. No. 10/979,677 filed 2 Nov. 2004; whichclaims the benefit of U.S. Provisional Application Ser. No. 60/569,007filed 7 May 2004; each of which is incorporated herein by reference inits entirety.

FIELD OF THE INVENTION

This invention relates to solid state light emitting devices such aslight emitting diodes, also called LEDs, and more particularly to suchdevices which produce achromatic light without hue (white light) orchromatic light with hue (colored light). The present invention is basedon the discovery that a highly efficient achromatic, chromatic andnon-visible light emitting device may be simply and economicallyfabricated utilizing a solid state light emitting diode die that in theabsence of certain elements of the following generates primary radiationwhich transfers its energy, radiatively or non-radiatively, to secondaryluminescent elements where the diode die and or the secondaryluminescent elements are in an enhancing and or protecting enclosure.The invention enhances and protects both the p-n junction and orluminescent elements associated with light generation instantaneouslyand over the long term.

BACKGROUND OF THE INVENTION

General illumination is a basic need of society which becomes mostevident when it is not otherwise available. Throughout the history oflighting innovation, the challenge facing the inventor and those engagedto practice the inventions have been to 1) coax more light from thedevice of interest, 2) produce the light more efficiently, 3) effect theproduced light in a manner that is physiologically preferred, 4) producethe aforementioned maximal light for longer periods of time and 5)manufacture the device that meets the first four criteria in a lowestpossible competitive cost. In almost all cases, the advancement of theart for nascent lighting devices has taken a long a tortuous pathrequiring innovation from a multitude of inventors and scientists andthe practicable application of these innovations in manufacturing andultimately in the marketplace. The more recent discovery of white lightsolid-state lighting from a single light emitting diode die (B. H.Baretz et. al., U.S. Pat. No. 6,600,175, filed on 26 Mar. 1996, issuedon 29 Jul. 2003; hereinafter “Baretz et. al. [2003]”) has elevated theheretofore chromatic solid-state lights unsuitable for generalillumination into a lighting innovation with providence; it is expected,to be an alternative device for indoor and outdoor lighting. It is thepresent day desire to improve the performance of achromatic solid-statelights, primarily, and chromatic light secondarily so that the currentdeficiencies for these devices based on p-n junction be resolved. Theinvention that I have made is a dramatic improvement in the utility ofsolid-state lights based on semiconductor p-n junctions in the contextof 1) light output, 2) light efficiency, 3) light projection andutility, 4) light generation durability and 5) the physiologicalappreciation of the light so produced.

The aforementioned invention of Baretz et. al. [2003] allows white lightfor general illumination to be generated using photons emanating from atleast one p-n junction which, when connected to a power supply with asuitable electrical current, initially generates the aforesaid photonsthrough a hole-electron recombination at the p-n junction. In contrast,earlier advances in general illumination allowed for white light to begenerated using photons emanating from a heated wire where the heat isgenerated by electrical current flowing through the wire or an arc ispassed through a medium with elements excitable by the electricalcurrent.

My current invention solves many of the problems that solid-statelighting presently experiences when using light-emitting diode die witha semiconductor p-n junction for the generation of achromatic andchromatic light, as defined hereinafter. My present invention focuses oncertain elements of the design of the lamp and allows for a broaderimplementation of achromatic light formation from a single diode diecapable of producing primary radiation in the visible or outside thevisible light spectrum.

Incandescent and Gas-Filled Incandescent Lamps

General illumination prior to the discovery of electrical stimulusrequired gas or other means of generating aflame. In the year 1810 SirHumphrey Davy, in the Royal Institution in London, using batteries andpieces of willow charcoal formed an electric bow or “arc”: thisexperiment laid the foundation for all subsequent “arc” lightingsystems. It is generally agreed by those examining the history oftechnologies impacting general illumination that Davy was also thefounder of incandescent electric lighting, as he at this early periodmade both platinum and carbon incandescent filaments and observed lightwhen powered by means of his proprietary battery. After describing hisexperiments with the arc light, Sir Davy has been reported toadditionally remark: “And a platinum wire 1/30 of an inch in thicknessand 18 inches long, placed in circuit between the bars of copper,instantly became red hot, then white hot, and the brilliancy of thelight was insupportable to the eye.” (W. J. Hammer in “The William J.Hammer Historical Collection of Incandescent Electric Lamps.” Reprintedfrom The Transactions of the New York Electrical Society, New Series,No. 4, 1913; hereinafter Hammer (1913).)

Relying on the discourse of Hammer (1913) and his insight into theindividual importance of innovations and inventions to improveincandescent lamps, it has been noted that the first English patent onthe incandescent electric lamp was that of De Moleyns in 1841. Heproposed to sprinkle finely divided carbon or graphite over the surfaceof an incandescent platinum wire. In 1858 Gardner and Blossom appliedfor a very early if not first American patent in this field; it—theclaims of the patent—being for a platinum lamp to be used for a railwaysignal lamp. Hammer additionally acknowledges the contributions of manyindividuals—Konn (carbon rod, in Russia), Bouliguine (graphite rod, inRussia), Lodyguine (carbon block bulb under nitrogen, in Russia; alsoplated platinum wire with tungsten in 1893), Staite (iridiumfilament-1848), Fontaine (France), Draper (platinum wire lamp), Sawyer(arched paper filament lamp), Maxim (patented a platinum lamp in 1879),and others—even if these earlier contributions did not lead to the“establishment of the commercial incandescent electric lamp.”

The English inventor Sir Joseph Wilson Swan has been generally creditedfrom many different resources used as references available to thegeneral public with creating the first electric light in 1860. Theinventor's lighting device could not really be used yet because thefilament burned up too quickly. Swan periodically improved his inventionand gave the world's first lighting demonstration in 1878.Unfortunately, the device was still not entirely practical, at the timeof the announcement, because of the short life of the filament.Nevertheless Swan remained a tour-de-force in the continuing evolutionof practical and practicable technologies for general illumination.

We highlight the absence of commercial practicality in the context ofdevice durability or operational longevity for a heated filament as thesubsequent and early inventive improvements and commercial implicationsfocused initially on perfection to the incandescence of the filamentitself. Since a filament is a material through which an electricalcurrent flows, the early research focused on changing the material, theprocess to make materials, and the process to make filaments from saidmaterials. Subsequently, as detailed more completely hereinafter, thecommercial practicality of incandescent lighting was found to bedetermined by many parameters of weightier significance than a solefocus on filament materials; it ultimately came to the realization ofmany that post-processing material effects, in the lamp itself, is ofparamount importance. The current state of affairs related to theproduction of achromatic light from a single p-n junction as claimed byBaretz et. al. [2003] similarly acknowledges that improvements to theperformance of the achromatic solid-state light can be accomplished byimprovements to the production of photons from the hole-electronrecombination. Heretofore, the focus on the commercial practicality ofsolid-state lighting has been on changing the semiconductor material,the process to make semiconductor materials, and more recently theprocess to make semiconductor devices from said semiconductor materials.As will become more apparent with complete specification of my inventioncontained herein, the methodology utilized to enhance the efficiency andmagnitude of achromatic and chromatic light will be a function ofimprovements to many components that make up a solid-state lamp: for asemiconductor material itself, the present invention will also allow forimprovement of hole-electron recombination in a lamp, for the very firsttime, by treatments within a lamp subsequent to the initial formation ofthe p-n junction.

Continuing with this discourse, notwithstanding the contributions ofSwan, who remained an important contributor to advancing the art ofincandescence, it is in the historical record that Henry Woodward ofToronto along with Matthew Evans patented an early light bulb in 1875.(H. Woodward and M. Evans, handwritten patent submitted in final form tothe Patent Branch of the Canadian Department of Agriculture, No. 3738,Jul. 24, 1874) In perhaps one of the earliest examples of intellectualproperty licensing, Thomas Edison bought the rights to their patent. In1879, it is generally understood, Thomas Edison finally completed thedevelopment of a practical incandescent light bulb after many hundredsof trials and errors. Interestingly from the perspective of innovationssubsequently patented considerably later thereafter, Woodward and Evansteach “We claim—the placing of carbons in lamps or other suitablevessels filled with rarified gas, possessing the property of notchemically combining with the carbon when in a state of incandescence .. . ” It is generally believed that nitrogen was the gas used byWoodward and Evans.

By the aforementioned references, it has been the general point of viewthat the greatest test that faced Edison was to find a substance for thefilament that could remain heated for days before burning up. Despiteall of the great inventions for general illumination that precededEdison, the practicality of functional general illumination remainedillusive; Edison believed early on that, regardless of which materialworked best, the filament is obliged to be contained in a vacuum. (T. A.Edison, U.S. Pat. No. 227,229, issued May 4, 1880). Perhaps moreelegantly than the environment, in which the incandescent filament wasto find itself in the invention of Edison (1880), was the additionalfocus on the filament itself: a small amount of material that had a veryhigh resistance to the current was his principal center of attention.

Although it is not generally appreciated, especially since the historyof his subsequent commercial activities focused on non-metal filaments,Edison's first experimental lamp was a platinum lamp, but he alloyediridium with the platinum, as had been done by Staite (who had patentedin 1848, it has been reported, a horseshow shaped iridium filament forlighting) before him. A spiral coil filament was developed and this lampwas known as Edison's platinum-iridium thermostatic regulating lamp. (T.A. Edison, U.S. Pat. No. 214,636; issued: Apr. 22, 1879)

Notwithstanding this early focus on metal which, since it was platinum—avery expensive commodity—that also left the end user with less thanoptimal performance, non-metals became the more immediate focus: thegoal was greater light output, greater durability and lowermanufacturing cost. Edison tried hundreds of non-metal materialsincluding bamboo and thread. It is well documented that Edison's successin October, 1879, with a carbonized cotton thread, when sealed in aglass bulb, lasted forty hours. (T. A. Edison, U.S. Pat. No. 223,898,issued Jan. 27, 1880). Subsequently, Edison found a better filament incarbonized strips of bamboo.

At the time of Edison's pioneering work, other innovators and inventorswere seeking to improve the performance of certain components used inthe incandescent lamp. Most of the effort focused—as did the effort ofT. A. Edison—on the non-metal filament and it is known to be the casefrom references in the general literature that Lewis Howard Latimer thenworking with the United States Electric Lighting Company (BridgeportConn.) invented a method of making carbon filaments (L. H. Latimer, U.S.Pat. No. 252,386, issued Jan. 27, 1882) for the Maxim electricincandescent lamp. (J. V. Nichols, et. al., U.S. Pat. No. 247,097,issued Sep. 13, 1881) At the same time, it has been noted by manylighting historians that in Germany, Siemens & Haske perfected a lightin 1878-1880 (differential arc lamp; also began to manufacture inGermany incandescent lamps of the design of Swan in 1882). In 1884,Latimer himself began to reportedly collaborate with Edison.

The widespread use of urban street lighting began with the differentialarc lamp built in 1878 by Friedrich von Hefner-Alteneck, the chiefdesigner at Siemens & Halske. In this lamp the burned-down carbon rodsproducing the light could be regulated automatically and several lampscould also run together off a single generator.

By 1890, eleven years after the successful completion of his firstpractical incandescent light, Edison had organized his variousbusinesses into the Edison General Electric Company. It stands to reasonthat commercial efforts were in their full force to practice theinventions related to incandescent lamps as it had been over a decade inwhich the carbon filament as implemented by Edison (perhaps not uniquelybut with sufficient skills and know-how so as to technically lead) hadan opportunity to be further developed and improved.

At the same time of the commercialization efforts of the patents ofEdison General Electric Company, the Thomson-Houston Company and thevarious companies that had merged to form it were also in an excellentposition with patent rights necessary to commercialize and offer for thepublic good products in the electrical industry. In an 1890 catalogue[The Thomson-Houston Electric Company; Form B5-5700; Boston Dec. 1,1890], the latter indicates that they make superior incandescent lampsas theirs “are manufactured under the well known Sawyer-Man patents”. Aswith the efforts of Latimer and Edison himself, the Sawyer-Man patentsrelated to carbon filaments. In an issued United States patent in thesame period, Edison discusses the different capping used by Westinghouseand by Sawyer with the claims of the Edison capping—for universalscrew-in receptacles revealing quite clearly the different functionalforms of the same underlying technology. (T. A. Edison, U.S. Pat. No.438,310 issued on October, 1890) In 1892, these two majorcompanies—Edison General Electric Company and the Thomson-HoustonCompany—combined to form the General Electric Company. About the sametime, the foundations for what was to become Koninklijke PhilipsElectronics N.V. were laid in Eindhoven, the Netherlands, in 1891, forthe purpose of making carbon-filament lamps and by the turn of thecentury was one of the largest producers in Europe (in 1983 Philipsacquired the lighting business of Westinghouse).

While carbon filaments where being invented for incandescence, A. vonWelsbach produced the first successful metal filament by using osmium(platinum filaments not previously been successful). Von Welsbach, whopurportedly discovered praseodymium and neodymium near this time, wasinvestigating metals for gas mantles, gas mantles being an importantelement of gas lighting devices. Starting first with platinum, thenosmium, von Welsbach found a means of producing a fine wire of osmium.(1. C. A. R. von Welsbach, Great Britain Patent GB189801535; issue dateJan. 19, 1899; 2. C. A. R. von Welsbach, Great Britain GB190007210,issued date Jan. 26, 1901. 3. Oesterreichische Gasgluchlicht andElectricitates-Gesellschaft of Austria, Great Britain PatentGB189910241, issued date May 12, 1900.) Von Welsbach used the osmiumwire as a filament in the Auer-Oslight, which he introduced commerciallyin 1902, the metal filament light bulb was a huge improvement on theexisting carbon filament designs, lasting much longer, using about ½ theelectricity for the same amount of light, and being much more robust.

Osmium is an element however that was expensive alternatives to whichwere under study. Contemporaneous to the pioneering work on vonWelsbach, the chemist Werner Bolton was engaged to researchincandescence with Siemens & Halske in 1896. At the time of theintroduction of the Auer-Oslight, Bolton made the discovery thattantalum was an ideal material for making metal filaments andincandescent lamps. The first tantalum metal-filament incandescent lampswere available on the market in 1905—about the time of innovations of adifferent nature from General Electric as we will reveal later—and by1914 over 50 million had been produced worldwide using Bolton's method.(Siemens & Halske; Great Britain patent GB190523098; issued date: Dec.21, 1905)

In addition, and approximately at the same time that the applicant“Siemens & Halske AG of 3 Askanischer Platz, Berlin, ElectricalEngineers” claimed improved manufacture of glow lamps with incandescencebodies of tungsten molybdenum and similar metal (Siemens & Halske,1905), another entity which it is claimed the first to introduce andtrademark the name OSRAM—Gasgluehlicht AG Auergesellech ofBerlin—claimed, as Manufacturers, in their 1905 patent “Filaments ofrefractory, non-precious metals, such as molybdenum, tungsten, vanadium,and tantalum, are freed from carbon, which remains from the organicbinding-material, by treatment at a white heat with hydrogen containinga small proportion of water-vapor or other oxidizing-agent.”(Gasgluehlicht AG Auergesellech; Great Britain patent GB190519379;issued date: Mar. 29, 1906)

Clearly the focus of the innovators, inventors and manufacturers—allseeking to improve the performance of carbon filament lamps—were now onmetal filaments. The commercial availability of Auer-Oslight from vonWelsbach, of lamps from Siemens & Halske using the method of Bolton, andthe disclosures of the manufacturer Gasgluehlicht AG Auergesellech,indicate that filaments of osmium, tantalum, and “molybdenum, tungsten,vanadium and tantalum”, respectively were the focal point. This paralleltechnology development (focus on metal filaments), as well as parallelmarketing and other business strategies, first in competition and thenin collaboration ultimately led to OSRAM being formed in 1919 by Siemens& Halske, Gasgluehlicht AG Auergesellech and AEG (AllgemeineElektricitäts Gesellschaft; originally German Edison Company itselfformed in 1883).

In 1904 the Siemens-Halske Co. tried to apply the drawing process theyhad developed for tantalum to the production of filaments of the morerefractory metals, for example tungsten. The brittleness and lack ofductility of tungsten prevented their attaining success by this method,although later, in 1913-1914, it was demonstrated that fused tungstencould be rolled and drawn at very high temperatures, using very smallreduction steps. Nevertheless, as the above discussion clearly shows,there were improvements in metal filaments with these Europeanmanufacturers so that tungsten filaments began as early as 1906 tocommercially substitute tantalum as the metal filament for incandescentlamps. (Westinghouse Metallfaden Gluehlampenfabrik GmbH, Great BritainPatent GB191003610, Oct. 6, 1910)

Concurrently, metallized carbon filaments were developed by GeneralElectric Company and Westinghouse; (A. Lederer and Westinghouse MetalFilament Lamp Company, Ltd.; Great Britain Patent number GB191005388,issue date Mar. 2, 1911) lamps containing these filaments were marketedas so-called GEM lamps. (W. R. Whitney of the Massachusetts Institute ofTechnology, Great Britain Patent number GB190424788, issue date of Nov.9, 1905; also Great Britain Patent number GB190426917, issue date ofMar. 2, 1905) While metallized carbon was better than carbon, it wasapparently the penultimate solution to an optimal metal filament.Westinghouse (the company) as did others worked on making tungstenfilaments for incandescent lamps by refining the method of Auer vonWelsbach originally applied when preparing osmium filaments.(Westinghouse Metal Filament Lamp Co., Ltd., Great Britain Patent numberGB190814942; issue date May 6, 1909) In the method of Westinghouse(1909) tungsten trioxide is reduced by zinc (at 800° Centigrade) afterwhich it is washed to remove the unused zinc and the resultant zincoxide; the method was claimed by generous attribution apparently unusualamong other patentees in that era to be a refinement of a methoddescribed by Delepine.

It was not, however, until 1909 that William Coolidge, in America at theGeneral Electric Research Laboratories, was successful in making ductiletungsten from the metal powder by suitable heat treatment and mechanicalworking. Coolidge succeeded in preparing a ductile tungsten wire bydoping tungsten oxide before reduction. The resulting metal powder waspressed, sintered and forged to thin rods. Very thin wire was then drawnfrom these rods. The very first Coolidge bulbs were marketed in the U.S.under the Osram trade name, a name already in use in Europe and a namethat would resurface from time to time in the United States.

The General Electric chemist, Irving Langmuir, trained at ColumbiaUniversity and who won the 1932 Nobel Prize in chemistry for his work onsurface chemistry, is frequently credited with discovering the tungstenfilament of choice in 1915 for incandescent lamps in general and as theinventor of the gas-filled (nitrogen or mercury vapor) tungsten lamp,more specifically. (I. Langmuir, Great Britain Patent GB191417326; issuedate Apr. 1, 1915. I. Langmuir, U.S. Pat. No. 1,180,159, issued Apr. 18,1916. I. Langmuir, U.S. Pat. No. 1,246,118, issue date Nov. 13, 1917. P.C. Hewitt, Great Britain Patent GB191208086, issued date Oct. 10, 1912.O. Krause, Great Britain Patent GB191011107, issue date Jan. 12, 1911.)Langmuir's description of the invention teaches that the nitrogen gas,if used as the atmosphere within the gas filled lamp, is to bescrupulously dried over, for example, phosphorous pentoxide and hislamp, he claimed, would burn for over 1,000 hours. The use of nitrogenatmosphere in a tungsten filament lamp was novel to Langmuir; theintroduction of nitrogen in a carbon-filament lamp of earlierincandescent lighting generations was previously suggested and was afailure according to Langmuir since he claimed at the temperatures atwhich the carbon filament found itself—when providing illumination—weresuch that carbon and nitrogen could react to form cyanogens andparacyanogen. Note only does a brown powder of “paracyanogen” form onthe surface of the bulb effectively reducing luminance emanating therefrom, but the reaction also weakens the carbon filament reducing theoperational burn time of the incandescent lamp. Langmuir claims thatnitrogen vapor does not react with heated tungsten filament, although itdoes react with vaporized tungsten (sublimed tungsten) to form tungstennitride “which is less opaque” than tungsten itself. Langmuir teachesthat other than nitrogen, the following gases may be used with atungsten filament: argon, mercury vapor, or other gas having poorconductivity of heat and that pressure at least 1 atmosphere arepreferred. (Langmuir, 1916). With regard to the role of mercury vapor incountering the deleterious effects of water vapor, Langmuir (or at leastthe agent on behalf of the inventor) states “I do not wish to advance orto be restricted to any particular theory.” (Langmuir, 1917) Similarstrategies were employed with a molybdenum filament. (BritishThomson-Houston Company, Ltd., Great Britain Patent number GB191505741,issue date Apr. 6, 1916)

The convection loss from a filament was found to be dependent on whatLangmuir termed the “shape factor” of the filament as well as thethermal conductivity of the fill gas. Very close to the filament in anordinary household lamp the heat is conducted away from the filament;out away from the filament the heat is than convected away. The regionabout a filament through which conduction takes place is a fewmillimeters thick: this region is referred to as the Langmuir film orsheath. It should be mentioned, especially in the context of my presentinvention to be more fully described hereinafter, that this boundarylayer, through which conduction takes place, is present about any bodythat is heated relative to the surrounding gas atmosphere.

Langmuir's study of conduction-convection losses from heated bodies ledhim to the conclusion: the long filament length had to be effectivelyshortened to reduce the losses. This was accomplished by coiling thetungsten wire. Successful lamps have been made by double coiling andtriple coiling. The conduction-convection loss is relatively insensitiveto the diameter of the resulting coil.

While coiling had the effect of reducing gas losses, another importanteffect occurred. Bulb blackening was reduced considerably because someof the diffusing tungsten atoms that evaporated during normal lamp usagewould diffuse back to the filament and deposit themselves on thefilament instead of the inside of the glass bulb. This is an extremelyimportant observation as the so-called regenerative effect is asubstantial reason why gas-filled lamps—as opposed to vacuumlamps—enjoyed support from manufacturers and end users (both gas-filledand vacuum incandescent lamps are routinely used today).

Another effect also occurred because of the gas filling, which initiallywas nitrogen but eventually was a nitrogen-argon mixture. Lamps werefilled roughly at 80% of atmospheric pressure. During normal operationof household lamps the operating pressure then rose to about oneatmosphere (750 Torr). After some of the evaporating filament atomsreached the outer boundary of the Langmuir layer the convection currentswould carry most of them upwards to deposit on only a portion of theglass surface rather than the entire bulb, as in vacuum lamps. Thisreduced the overall light output loss.

A gas fill has advantages in permitting a higher filament temperaturefor a given life expectancy and the higher the filament temperature, thegreater the light output—this is the essence of incandescence whichgenerates illumination as a black body irradiator (Stefan-Boltzmann lawstates that the total energy j* radiated per unit surface area of ablack body in unit time (black-body irradiance), is directlyproportional to the fourth power of its thermodynamic temperature T[j*=σT4] and where the non-fundamental constant of proportionality a iscalled the Stefan-Boltzmann constant with a value of 5.670400×10-8 J s-1m-2 K-4). But as noted the gas also conducts heat—this permits energy toexit the filament by means other than radiation so this is anon-radiative loss. If the heat conduction of the gas reduces efficiencymore than the higher allowed filament temperature increases efficiency,then the light bulb design is better with a vacuum than with a gas (thereason that gases of low heat of conductivity were required). As itturns out, argon and the argon-nitrogen mixture are not the best.Krypton conducts heat less than argon does, and xenon conducts heat lessthan even krypton does. In cases where argon is only slightly worse thana vacuum, krypton and xenon are better than a vacuum. In addition, thelarger atoms of krypton and xenon are better for “bouncing evaporatedtungsten atoms” back onto the filament than the smaller atoms of argonand nitrogen are. Interestingly, the Stefan-Boltmann law, majorcontribution to the field of theoretical physics, was originally andexperimentally discovered by Jožef Stefan in 1879, concurrent with theendeavors of Edison and others to develop a practical device for generalillumination, (J. Stefan, “Ober die Beziehung zwischen derWarmestrahlung and der Temperatur” (On the relationship between thermalradiation and temperature), The Bulletins from the Sessions of theVienna Academy of Sciences, Mar. 20, 1979) demonstrating once again theparallel activity between technology, fundamental science, and productsfor the public good.

The bendable tungsten wire invented by Coolidge gave an incandescentlamp of 10 lumens per watt output and (history has it) a strongportfolio of issued patents assigned to the benefit of General ElectricCompany. The Langmuir gas-filled lamp—with the tungsten filament ofCoolidge and nitrogen gas, as an example—obtained at least 12 lumens perwatt in performance. Both Langmuir's and Coolidge's tungsten filamentlamps—using the tungsten filament methodology apparently unique toGeneral Electric—appeared on the market in 1913 under the “Mazda” tradename.

It is inevitably the case that the technology that brought incandescentlamps to its ultimate commercial reality—principally driven by thepractical and practicable inventions of Coolidge and Langmuir—hasreached a point of sophistication-90 years hence—unimagined at the timeof these practical commercial inventions. Today, one finds thoria dopedtungsten wire or rhenium doped tungsten wire in vibration-resistantincandescent lighting. (W51 Tungsten Wire (0.7% Thorium) and H30Tungsten Wire (3% Rhenium) from Toshiba Corporation; Sylvania Type 3RW(3% Rhenium tungsten wire) from Osram Sylvania Materials & ComponentsTowanda Pa.) Co-dopants may include aluminum, silicon and potassium.These doped tungsten filaments are non-sagging wires and are producedafter doping the tungsten powder—ingots are made from this dopedtungsten powder by sintering using electric heating and finally wiresare drawn. (W31 is a standard tungsten filament available from ToshibaCorporation; W91 is a non-sagging wire for halogen lamps where they areused at higher temperatures than usual lamps.)

The Mazda trade name first appeared in 1909 when the General Electrictantalum filament incandescent lamp replaced their 1904 improved newcarbon-filament lamp—the GEM lamp—after only five years on the market.At that time, the European tantalum filament incandescent lamps werereceiving considerable attention. General Electric created a trade-name,Mazda, taken from the Persian (Zoroastrian) god of light, Ahura Mazdah.The Mazda name first appeared in 1909 on tantalum-filament lamps, andthen on first generation tungsten lamps made under license from Europe.General Electric also licensed the trade name to their subsidiaryNational Electric Lamp Companies, to Westinghouse and to BritishThomson-Houston and many of the technological improvements wereultimately marketed under the Mazda trade name. We highlight this pointto caution the reader that Mazda lamps are not always synonymous withthe method of Coolidge and Langmuir (for that matter, the trademarkOsram lamps at that time was not always synonymous with producers andtechnology of the aforementioned merged business entity-Osram; thetrademark GEM lamps were not always synonymous with the invention ofmetallized carbon filaments). General Electric viewed their breakthroughlamps of Coolidge and Langmuir heritage as second-generation tungstenfilament lamps: Mazda B lamps. The earlier, European lamps wereinformally considered “Mazda A” lamps. (GE continued using the Mazdaname until 1949.)

As is frequently the case, the presence of gas in incandescent lamps hada long history prior to the invention and research of Langmuir, some ofwhich we have already highlighted and presented as references for theprior art preceding the invention of Langmuir. It has been reported thatgas-filled incandescent lighting was tried by others: 1840, W. R. Grove,platinum, air; 1845, J. W. Starr, platinum, air; 1856, C. de Changy,platinum, air; 1859, M. G. Farmer, platinum, air; 1872, A. M. Lodyguine,graphite, nitrogen; 1875, S. A. Kosloff, graphite, nitrogen; 1878, St.George Lane-Fox, platinum-iridium, air or nitrogen; 1879, Sawyer-Man,carbon, nitrogen; 1894, The Star Electric Lamp Co., carbon, heavyhydrocarbons in “New Sunbeam” lamp; 1894, Waring Electric Co., carbon,low pressure bromine in “Novak” lamp; 1901, A. E. G., carbon, lowpressure carbon monoxide; and 1908, Hopfelt, carbon, mercury. (All ofthe above notations were obtained from the reference: Arthur A. BrightJr., The Electric-Lamp Industry: Technological Change and EconomicDevelopment from 1800 to 1947.)

During the same period that tantalum filament incandescent lamps wererealizing commercial success and the researchers at Siemens and GeneralElectric and others were focusing on tungsten, we would be remiss not tonote that the U.S. lighting company Sylvania (the North Americanoperations of which are now owned by Osram) traces its origins to theHygrade Incandescent Lamp Company which in 1909 began to manufacture andsell carbon-filament light bulbs and, by 1911, it is claimed in theirhistorical presentations, tungsten filament light bulbs. Whether thetungsten lamps of Hygrade were more like those emanating from Europe ormore like the refinements ultimately made by Langmuir are unclear.

Notwithstanding the invention of Langmuir (1916), a few years later, inan issued Great Britain patent, Osram-Robertson Lamp Works of GreatBritain claimed coiled tungsten filaments within a lamp bulb and thatthe lamp envelope “may be filled with gas such as argon.” (T. J. Sack,Great Britain Patent GB123249; issue date Feb. 20, 1919.) Robertson LampWorks in Great Britain gained its origins when patents for the originalcarbon filament incandescent expired in 1893 and it gained know-how toproduce carbon filaments and vacuum incandescent lights. The Osramincandescent lamp from Robertson Lamp Works used a tungsten-molybdenumdoped filament and argon gas.

The manufacturing methodology for incandescent lamps was at a relativelyadvanced stage by the time tungsten filaments became entrenched. Whetherthe incandescent lamp is one under vacuum or, ultimately filled withnitrogen, argon, or mixtures thereof, the glass envelope is sealed witha burner which closes off the exhaust port (from which the vacuum isapplied). The electrical leads that traverse through the glass envelopeare made of metal. Some metal must be chosen which will expand whenbeing heated, and contract when cooling, at exactly the same rate asglass, so that the two act as if they were one. This equal expansion andcontraction must, moreover, be maintained all through the wide range oftemperatures from that of molten glass to ordinary atmospherictemperatures. As noted previously, Sawyer and Edison used platinum wire.It is clear then to those of ordinary skill that the methodology ofsealing a glass enclosure with electrical leads protruding through thesealed enclosure is a relatively routine manufacturing process and isused for incandescent lamps of general illumination size as well asminiature incandescent lamps approximating the size of solid-statelamps. It will become apparent that embodiments to my present inventionas more fully described hereinafter utilize these manufacturingcapabilities mentioned in this paragraph.

The tungsten-halogen incandescent light of more recent vintage issimilar to conventional non-halogen incandescent light in that itemploys a tungsten filament in a gas-filled, light-transmitting envelopeand emits the same type of light. The major differences are that a traceof halogen vapor (e.g., iodine or bromine) is added to the inert fillgas, the gas pressure (7-8 atmosphers) and bulb temperature (250° C. to600° C.) are much higher than in non-halogen lamps, and the bulb is madeof fused quartz (silica, SiO2), high-silica glass or aluminosilicate“hard” glass to withstand the high operating pressures and temperatures.Lastly, there is a higher color temperature, 2800° K to 3400° K forstandard halogen product. Due to all of this, both material and process,halogen products are more costly to manufacture. Tungsten-halogen lampsoperate in a “halogen regenerative cycle” which permits the use of morecompact bulbs than those of conventional tungsten-filament lamps ofequal ratings, and also permits either increasing lamp life toapproximately twice that of conventional tungsten filament lamps havingcomparable wattage and color temperature or increasing colortemperatures and lumen outputs to values significantly above those ofconventional tungsten filament lamps having comparable life and wattage.

As we noted before and comment further so as to highlight the benefit ofhalogen, in conventional gas-filled tungsten-filament lamps, tungstenmolecules evaporate from the hot filament, are carried by convectioncurrents of the inert fill gas to the relatively cool inner surface ofthe bulb, and are deposited to form a thin film which graduallyincreases in thickness during the life of the lamp. These phenomenacause depreciation of lumen output and efficacy in two ways. First,deposition of the evaporated tungsten on the bulb wall builds up a filmof increasing opacity which absorbs increasing portions of the lightproduced by the filament and thus reduces the total light output.Second, evaporation of tungsten from the filament reduces the filamentwire diameter, increasing the resistance and thus (at constant voltage)decreasing the amperes, wattage, lumens, lumens per watt, and colortemperature.

In tungsten-halogen lamps, the effects described above are reduced orretarded by the regenerative action of the halogen cycle, which operatesby virtue of the temperature gradient between the filament and the bulb.As a general concept:

(1) The filament, fill gas, and bulb are initially at some lowtemperature (e.g., ambient, for a cold start).

(2) When power is applied, the filament rapidly rises to its operatingtemperature (2800K to 3400K depending on application), heating the fillgas and the bulb. The bulb wall rises to an operating temperature of400° C. to 1000° C., and the fill gas rises to temperatures ranging fromthat at the filament to that at the bulb wall. This temperature gradientcauses convection currents in the fill gas.

(3) As the bulb wall rises above temperatures in the range 200° C. to250° C. (depending on nature and amount of halogen vapor), the halogencycle begins to operate. Tungsten molecules evaporated (more accuratelysublimed) from the filament combine with the halogen vapor to form atungsten halide (e.g., tungsten iodide or tungsten bromide). The halidedoes not condense on the hot wall of the bulb but is circulated byconvection back to the region of the filament.

(4) At the filament where the temperature exceeds 2500° C., the tungstenhalide dissociates, the tungsten is deposited on the filament. The freehalogen vapor is recirculated to continue the regenerative cycle. Thiscycle thus keeps the bulb wall clean by preventing deposition oftungsten and results in much higher lumen maintenance over the life ofthe lamp than that obtained for conventional tungsten-filament lamps.

The utilization of gas to regenerate the filament is a defining reasongas enclosures are utilized in incandescent lighting although tangentialbenefits have been noted in our discussion herein.

To maintain the high temperatures and pressures required for operationof the halogen cycle, tungsten-halogen lamp bulbs are significantlysmaller and have generally thicker walls than the bulbs of non-halogenincandescent lamps of comparable wattage.

Atmospheres of tungsten-halogen lamps comprise an inert gas with about0.1% to 1.0% of a halogen vapor added. The inert gas may be xenon,krypton, argon, or nitrogen, or a mixture (e.g., krypton/argon orargon/nitrogen) having the highest atomic weight consistent with cost aswell as arc-resistance suitable to the lamp design and the operatingvoltage. The halogen vapor may be pure iodine (I2) or a compound ofiodine (e.g., CH3I) or of bromine (e.g., HBr, CH3Br, or CH2Br2). Iodineis still used in long-life lamps for general illumination but bromine isnow used in most tungsten-halogen lamps, especially those forphotographic and reprographic applications. The minimum bulb walltemperature for operation of the halogen-cycle is about 200° C. forbromine which is significantly lower than the 250° C. for iodine.Bromine is also colorless while iodine has a very slight absorption inthe yellow-green.

Unlike conventional gas-filled tungsten-filament lamps which operatewith an internal gas pressure of about one atmosphere, mosttungsten-halogen lamps operate with an internal gas pressure of severalatmospheres to further reduce the rate of tungsten evaporation. Thecombined effects of higher pressure and the halogen cycle give halogenlamps much longer life than that of comparable non-halogen incandescentlamps operating at the same filament temperatures. Conversely, when thetwo types are designed for equal life, halogen lamps will operate athigher filament temperatures with consequently greater luminance andefficacy.

One can see that in order to improve incandescent lamps to where we aretoday, first the underlying component that effects the lightemission—the filament—needed to be optimized, second the enclosure thathoused the filament needed to be designed for maximum light output, andfinally the environment in which the active component, the filament, ishoused needed to be perfected. At the same time incandescent lamps havebeen improved and optimized, for all of the five factors previouslymentioned (brilliance, efficiency, cost, physiological appeal, anddurability), other fundamental means of light emission were beingdiscovered. Among the alternative techniques of generating light forgeneral illumination are those based on luminescence.

Cold Light from Mercury Vapor Lamps

The term “luminescenz” was first used in 1888 by Eilhardt Wiedemann,German physicist, for “all those phenomena of light which are not solelyconditioned by the rise in temperature.” By the rise in temperature,Wiedemann referred to the fact that liquids and solids emit more andmore radiation of shorter and shorter wavelengths as their temperatureincreases, finally becoming perceptible to the eye as the materialbecomes red hot and then white hot. This is incandescence or “hotlight,” in contrast to luminescence or “cold light.”

The most notable cold light is commonly referred to as a fluorescentbulb or as a tube light. Fluorescent light bulbs are long, thin glasstubes that are coated on the inside with a white powder called“phosphor.” In order to turn them on, you must connect them to a devicecalled a ballast. Most ballast is hidden inside the lighting fixture,usually behind a piece of sheet metal. When you flip a switch to turn onthe lights, what you are actually doing is turning on the ballast. Theballast “turns on” the fluorescent lamp by passing electricity throughthe tube. The electrical current causes the gas inside the lamp to giveoff ultraviolet energy. The ultraviolet energy hits the phosphor andgets converted to light. When all is said and done, it has been foundthat fluorescent lamps use less electricity than incandescent lamps andthey are less expensive to operate.

In 1857, the French physicist Alexandre E. Becquerel who hadinvestigated the phenomena of fluorescence and phosphorescence,theorized about the building of fluorescent tubes similar to those madetoday. Alexandre Becquerel experimented with coating electric dischargetubes with luminescent materials. The work of Becquerel occurred aroundthe time of the first American patent on incandescence, said patentmentioned earlier.

The inventor Peter Cooper Hewitt, patented the first mercury vapor lampin 1901. (P. C. Hewitt, U.S. Pat. No. 682,699; issue date Sep. 17,1901). The low pressure mercury arc lamp of Peter Cooper Hewitt is thevery first prototype of today's modern fluorescent lights. A fluorescentlight is a type of electric lamp that excites mercury vapor to createluminescence. (P. C. Hewitt, Great Britain Patent number GB190609253;issued date Sep. 13, 1906. P. C. Hewitt, Great Britain Patent numberGB190424470, issue date Feb. 2, 1905.) It is generally believed that thework of Peter Cooper Hewitt built on the mid-19th century work of GermanJulius Plucker and Heinrich Geissler. By passing an electric currentthrough a glass tube containing tiny amounts of a gas, Plucker andGeissler found they could make light.

Peter Cooper Hewitt began developing mercury-filled tubes in the late1890s, and found that they gave off an unappealing bluish-green light.The amount of light, however, was startling. While the utility of theHewitt design was recognized not to be suitable for general illuminationin the home, the benefit for the photographic studios and for industrialuse were compelling. Hence, the commercialization of the invention ofHewitt (1901) rested with the Cooper Hewitt Electric Company, controlledby George Westinghouse, and, in 1902, the Cooper Hewitt Vapor LampCompany and Westinghouse Cooper Hewitt Company, LTD.

To improve on the color of the Hewitt lamp, Charles Bastion, who alsosuggested if not reduced to practice a mercury vapor lamp in 1903, alsosubsequently claimed to use rhodamine as a modifier to emit redradiation in 1904. (C. Bastion, Great Britain Patent number GB190409718,issue date Mar. 30, 1905). Rhodamine is a fluorescent organic dye incommon use even today in many implementations other than generalillumination. Others invented similar technologies to provide a redcomponent to the other bluish-green light, clearly an early effort tofocus on the physiological aspects of lighting: to the customer, thequestion is whether artificial light is aesthetically appealing. Thisphysiological aspect remains to this day and is characterized by termssuch as color rendering index and color temperature.

The inventor James Robinson noted that neon or rhodamin fluorescentscreens can be introduced to generate red fluorescence. (J. Robinson,Great Britain Patent number GB284746; issue date Jan. 30, 1928) Thedevelopment of improved mercury vapor lamps that utilized rhodamin orlike organic fluorescers (perylene, chrysene, fluorescein, rhodamine,ethylviolet and malchite green) would continue. (Johnson, P. D., U.S.Pat. No. 4,469,980, issue date Sep. 4, 1984)

Ultimately, Cooper Hewitt lamps proved cumbersome to use. The necessaryballast was heavy, and the lamps each contained as much as a pound ofmercury. Development of tungsten filament incandescent lamps in the1910s provided almost as much efficiency as the mercury tubes, but witha much better color. In due course, General Electric bought the CooperHewitt Company in 1919 and ultimately utilized the Cooper Hewittoperation to manufacture fluorescent lamps a legacy that more recentlybecame apparent as the factory-turned condominium received recognitionas a Superfund site. (1. R. Cahill, “HOBOKEN CLEANUP PLAN FOR GRAND STSUPERFUND SITE: EPA PROPOSES CLEANUP PLAN FOR GRAND STREET MERCURYSUPERFUND SITE IN HOBOKEN AND PERMANENT RELOCATION OF RESIDENTS”; PressRelease of U.S. Environmental Protection Agency, Records Center, 290Broadway 18th floor New York, N.Y., Jul. 9, 1997 wherein it was noted:Both the General Electric Company (GE) and the Cooper-Hewitt ElectricCompany manufactured mercury vapor lamps in the building at 722 GrandStreet from about 1910 to 1919 and again from 1948 to 1965. 2. NarendraP. Singh, MD, MS, CIH, “PUBLIC HEALTH ASSESSMENT: GRAND STREET MERCURYSITE HOBOKEN, HUDSON COUNTY, NEW JERSEY”, Agency for Toxic Substancesand Disease Registry, U.S. Department of Health and Human Services,CERCLIS NUMBER: NJ0001327733, Nov. 27, 1998) Clearly alternatives toheavy metals such a mercury is an absolute requirement for a technologyto be practicable.

An alternative to the mercury vapor lamp of Hewitt (and the pound ofmercury each lamp required) was the carbon dioxide and or nitrogenfilled tubes of D. McFarlan Moore. These lamps had a practicaldisadvantage that the lamps were over 250 feet in length. As the effortof Moore and Hewitt coincided with the discovery of the optimal tungstenfilament lamp of Coolidge and Langmuir, as previously referenced, theefficiency standard for general illumination was on the rise. As aresult, the impractical Moore lamp soon disappeared from the market forgeneral illumination. Nevertheless, building on Moore's work, GeorgesClaude of France developed neon tubes in 1910 and showed that adischarge lamp could give 15 lumens per watt—a not too shabby lightoutput if one notes that Langmuir's tungsten filament lamp was then at12 lumens per watt—but only if one wanted red light. In that red lightis near the photopic minimum, a lumen output greater than that of whitelight which covers the photopic maximum is quite impressive. AdditionalEuropean work resulted in a high-intensity mercury vapor lamp (fromGeneral Electric Company of England) in 1932. This lamp used a tinyfraction of the mercury needed for Cooper Hewitt lamps, had a screwbase, and gave 40 lumens per watt, though its color was still poor.

A collaboration of GEC in England, Philips in The Netherlands, and Osramin Germany produced a low-pressure sodium lamp also in 1932. The key tothis lamp lay in a special glass that could withstand the corrosiveeffects of sodium. The light was a stark yellow suitable only for use inapplications like street lighting, but efficacy started out at 40 lumensper watt (and ultimately reached about 100 lumens per watt thirty yearshence).

In the late 1920s and early 1930s, it became clear that neon tubescoated with phosphors have utility. A phosphor is a material whichabsorbs one type of light and radiates another. A German patent in 1927contained most of the features of a fluorescent tube, but the lamp wasnot produced. It is reported that a green lamp giving 30 lumens per wattwas demonstrated in 1934.

In 1936, tubes using low-pressure mercury vapor and a coating ofphosphors were demonstrated to the Illuminating Engineering Society. In1939, both General Electric Company and Westinghouse Electric introducedfluorescent lamps at both the New York World's Fair and the Golden GateExposition in San Francisco.

More specifically, the development of the “fluorescent lamp” which ledto the commercial introductions mentioned in the immediately precedingparagraph was by general acclaim pioneered by three German scientists,Friederich Mayer, Edmund Germer and Hans Spanner. They introducedpre-heating and a fluorescent coating in 1926 which gave a higher lightoutput and allowed the lights to operate on a lower, but still high,voltage. Together with Friedrich Meyer and Hans Spanner, Edmund Germerpatented an experimental fluorescent lamp in 1927. (F. Meyer, et. al.;U.S. Pat. No. 2,182,732; issued date Dec. 5, 1939)

Concurrent with the invention of Germer, Meyer and Spanner, the inventorGeorge Inman lead a group of General Electric scientists researching animproved and practical fluorescent lamp. The team designed a practicaland viable fluorescent lamp that was awarded, after five years ofprosecution, a United States patent. (G. E Inman; U.S. Pat. No.2,259,040; issue date Oct. 14, 1941)

According to the discourse presented within The GE Fluorescent LampPioneers and which we have relied on to accurately reflect thetechnology relationships, “On Oct. 14, 1941 U.S. Pat. No. 2,259,040 wasissued to George E. Inman; the filing date was Apr. 22, 1936. It hasgenerally been regarded as the foundation patent. However, somecompanies were working on the lamp at the same time as GE and someindividuals had already filed for patents. GE strengthened its positionwhen it purchased a German patent that preceded Inman's. GE paid$180,000 for U.S. Pat. No. 2,182,732 that had been issued to FriedrichMeyer, Hans J. Spanner and Edmund Germer. While one might argue the realinventor of the fluorescent lamp, it is clear that GE was the first tointroduce it.” In September 1935 the first tubular fluorescent lamp wasintroduced in Cincinnati USA by the General Electric Company.

A final form of a tube lighting (TL) fluorescent lamp was developed byAndré Claude, a cousin of George Claude (the inventor of the neon lightas noted previously), in Paris who sold his 1932 patent rights to theGeneral Electric Company. The public record indicates that the firstmajor installation of florescent lamps by General Electric Company wasat the US patent office in Washington USA in November 1936, andcommercial sale to the general public began in 1938. Osram introducedtheir fluorescent lamp in 1936. Philips NV started to produce theirfluorescent lamps in 1938. In 1942, A. H. McKeag of General ElectricCompany discovered the fluorescent properties of calcium and strontiumwhich doubled the efficiency of the phosphors incorporated intofluorescent lamps. Peter Ranby of General Electric Company discoveredfluorescent halophosphate in 1950 which when used in a fluorescent tubegives a pure white light. Philips introduced a lamp based on colortelevision technology in 1973 that gave a 50% increase in efficiency andsuperb color rendering.

In disclosure more related to organic luminophors as opposed to ceramicphosphors, the applicant NV Philips claimed “ . . . it is known toutilize high pressure mercury vapor discharge tubes in-conjunction withfluorescent materials which transform part of the rays emitted by thedischarge tubes into rays having a longer wavelength Said fluorescentmaterials include in particular red fluorescent rhodamine coloringmaterials. In practice, however, the use of these rhodamine coloringmaterials has not found favor since it has been found in practical usethat they lose their fluorescent properties within a short time.” (N. V.Philips Gloeiampenfabrieken, Great Britain Patent number GB454348,issued date Sep. 29, 1936) This represents an early discussion of thedegradation of down-conversion luminophors in non-solid-state lamptechnology. According to the invention, “said drawback is reduced to aconsiderable extent by utilizing red-fluorescent rhodamine coloringmaterials in conjunction with a mercury vapor discharge tube in whichthe mercury vapor has during operation a pressure greater than 10atmospheres. It has been found that in the spectrum of the light emittedat such high mercury-vapor pressures the line 2537 angstroms and theadjacent rays of greater wavelengths are suppressed to a comparativelyhigh extent, the band of suppressed wavelengths being the wider thehigher the pressure of the mercury vapor. With the device according tothe invention suppression of these rays of short wavelengths is veryadvantageous because as a result thereof the rhodamine preparation isirradiated by said rays to a much smaller extent, which is of greatimportance with respect to the fastness to light of the red-fluorescentrhodamine coloring materials.”

In addition to the efforts at N. V. Philips with rhodamin, and about atthe same time, in a patent as communicated fromPatent-Treuhand-Gesellschaft fur Elektrische Gluhlampen GmbH, GeneralElectric Company reported the use of two luminescent materials: aprimary luminescent material excited by the radiation (and moreparticularly ultra-violet radiation) from the discharge and a secondaryluminescent material excited by the luminescent radiation from theprimary luminescent material. (General Electric Company, Great BritainPatent number GB448887; issue date Jun. 17, 1936) Other patents fromGeneral Electric Company discuss alternative means of effectingdown-conversion with organic fluorescent dyes: “The luminescence andlight-fastness of a rhodamine dye dispersed in a resinous binder areimproved by mixing the solid dye with a molten resin in the absence ofany solvent adapted to dissolve both the dye and the resin. Resins ofthe glycerine-phthalic anhydride and formaldehyde-urea types may beused.” (General Electric Company, Great Britain Patent number GB474297;issue date Oct. 28, 1937) Other disclosures—all issued Great Britainpatent—relating to rhodamine and related organic luminescent dyes(eosin) as a down-conversion dye include:

(1) GB190308147; 1904-01-07; BURKE, JOHN BENJAMIN BUTLER

(2) GB477192; 1937-12-23; BRITISH THOMSON HOUSTON CO LTD

(3) GB456480; 1936-11-10; PHILIPS NV

(4) GB483662; 1938-04-22; PHILIPS NV

(5) GB503760; 1939-04-06; BRITISH THOMSON HOUSTON CO LTD

(6) GB190308147; 1904-01-07

Despite the extensive innovations using rhodamine, an organicfluorescent dye, it is not utilized in present day lighting as it hasnot yet been found a means to stabilize the rhodamine under theconditions of high luminance in an operating lamp, regardless of whetherthe lamp is a mercury vapor lamp or any other lamp.

The phosphors of more modern usage are generally of two types: Calciumhalo phosphates which are the main standard phosphors for fluorescentlamps (easy dispersible and require only simple suspension equipment)and triband phosphors (based upon inorganic material containing ‘rareearth’ elements where a combination of red, green and blue results in a50% increase in efficacy with regard to standard phosphors and excellentcolor rendering properties).

Examples of commercial ceramic phosphors for fluorescent tube lightingare from Philips Lighting Components located in Deurne/Maarheeze(Netherlands):

(7) Red Tricolor: Yttrium Oxide:Eu (Y2O3:Eu); 254 nm excitation—quantumefficiency 84%; UV-absorption 84%; wavelength at peak 613 nm; bandwidth(50%) 3 nm; excitation peak 203 nm; C.I.E chromaticity coordinates:powder x=0.643 y=0.344; lamp TLD 36 W x=0.576 y=0.326.

(8) Blue-Green Tricolor: Barium Aluminate Europium Manganese(BaMgAl10O17:Eu,Mn); 254 nm excitation—quantum efficiency 92%;UV-absorption 86%; wavelength at peak 450 nm; bandwidth (50%) 51 nm;excitation peak 248 and 308 nm; C.I.E chromaticity coordinates: powderx=0.144 y=0.142; lamp TLD 36 W x=0.152 y=0.170.

(9) Blue Tricolor: Barium Magnesium Aluminate:Eu (BaMgAl10O17:Eu); 254nm excitation; quantum efficiency 93%; UV-absorption 86%; wavelength atpeak 453 nm; bandwidth (50%) 51 nm; excitation peak 313 nm; C.I.Echromaticity coordinates: powder x=0.149 y=0.069; lamp TLD 36 W x=0.154y=0.068.

(10) Green Tricolor: Cerium Lanthanum Phosphate:Tb (LaPO4:Ce,Tb); 254 nmexcitation quantum efficiency 95%; UV-absorption 98%; wavelength at peak542 nm; bandwidth (50%); Line excitation peak 241 nm; C.I.E chromaticitycoordinates: powder x=0.343 y=0.579; lamp TLD 36 W x=0.319 y=0.537.

(11) Philips U1213 Halophosphate: Color Temperature: 2900 K; “WarmWhite”; Ca10(PO4)6(F,Cl)2:Sb,Mn NOTE: Color Temperature changes asfunction of Sb and Mn doping: Philips U1228 3500 K “White”; PhilipsU1225 4100 K “Cool White”; Philips U1242 5000 K “Tropical Daylight”;U1239 6500 K “Daylight”; Philips U1254 6500 K Daylight

(12) Philips U1234 Blue Fine: Ca10(PO4)6F2:Sb T

The library of ceramic phosphors is vast and the elements within areused in a wide variety of applications. For example, available fromToshiba Corporation are the following list of phosphors (in a cathoderay tube (CRT) application, the phosphor is brought to its excited stateby irradiation with an electron beam):

(1) CRT: Blue (P-22B): ZnS:Ag

(2) CRT: Blue (P-22B): ZnS:Ag+Pigment

(3) CRT: Green (P-22G): ZnS:Cu,Al

(4) CRT: Green (P-22G): ZnS:Cu,Au,Al

(5) CRT: Red (P-22R): Y202S:Eu

(6) CRT: Red (P-22R): Y202S:Eu+Pigment

(7) Blue: Three Band Lamp: 3(Ba,Mg)O,8Al2O3:Eu

(8) Blue: Three Band Lamp: (Sr,Ca,Ba)10(PO4)6,Cl2:Eu

(9) Blue-Green: Three Band Lamp: 3(Ba,Mg)O,8Al2O3:Eu,Mn

(10) Green: Three Band Lamp: (La,Ce)(P,Si)O4:Tb

(11) Red: Three Band Lamp: Y₂O₃:Eu

(12) Ultraviolet: Special Lighting: BaSi2O5:Pb

(13) Blue: Special Lighting: CaWO4

(14) Green: Special Lighting: Zn2SiO4:Mn

(15) Orange: Special Lighting: (Sr,Mg)3(PO4)2:Sn

(16) Deep Red: Special Lighting: 3.5MgO,0.5MgF2,GeO2:Mn

(17) Red: Special Lighting: (Y,Gd)BO3:Eu

(18) Blue-Green: Electroluminescent Panels: ZnS:Cu

(19) Green: Electroluminescent Panels: ZnS: Cu

(20) Orange: Electroluminescent Panels: ZnS: Cu,Mn

(21) x-Ray Intensifying Screen: Gd2O2S:Tb

A similar listing of phosphors are available from Osram SylvaniaMaterials & Components Towanda Pa.:

1) Blue-Green Lamp Phosphor: BaMgAl10O17:Eu:Mn (peaks at 456, 514 nmwith a 50 nm bandwidth)

2) Green Lamp Phosphor: (La,Ce,Tb)PO4:Ce:Tb (peak at 546 nm with a 6 nmbandwidth; a tricolor phosphor)

3) Green Lamp Phosphor: Zn2SiO4:Mn (Willemite, peak at 528 nm with a 40nm bandwidth)

4) Green Lamp Phosphor: (Ce,Tb)MgAl11O19: Ce:Tb (peak at 546 nm with a 9nm bandwidth; a tricolor phosphor)

5) Blue Lamp Phosphor: MgWO4 (peak at 473 nm, with a 118 nm bandwidth)

6) Red Lamp Phosphor: Y₂O₃:Eu

7) Red Lamp Phosphor: Mg4(F)GeO6:Mn

8) Red Lamp Phosphor: Mg4(F)(Ge,Sn)O6:Mn

9) Blue Lamp Phosphor: CaWO4:Pb (Scheelite)

10) Blue Lamp Phosphor: BaMgAl10O17:Eu

11) Blue Lamp Phosphor: Sr5Cl(PO4)3:Eu

12)Orange Lamp Phosphor: (Sr,Mg)3(PO4)2:Sn

13) White Lamp Phosphor: Ca5(F,Cl)(PO4)3: Sb:Mn

Among the phosphors of importance to fluorescent tube lighting are thosestudied by H. W. Leverenz (Ph.D., Chemistry, Stanford; FranklinInstitute Brown Medal in 1954 for his contributions to the developmentof the fluorescent lamp) and that which he invented, zinc berylliumsilicate manganese, was a major contribution to the development ofpractical fluorescent lamps. (See for example General Electric Company,Ltd. communicating from Patent-Treuhand-Ges. fur Elektrische Gluhlampen;Great Britain Patent number GB532501, issue date Jan. 24, 1941 where thephosphor zinc beryllium silicate (orange emitter) with magnesiumtungstate (blue green emitter) is described as a well-known compositionfor white light in mercury vapor lamps.) RCA, employer of Leverenz, byvirtue of its formation from General Electric Company, was commerciallyprohibited by mutual agreement from marketing and selling lightingappliances and the technology was assigned to the latter.

It is essential to provide additional background on another form of coldlight in order to truly appreciate the innovation that is my presentinvention. Another source of cold light is phosphorescence orphosphorescent phosphors.

Phosphorescent pigments are those in which excitation by a particularwavelength of visible or ultraviolet radiation results in the emissionof light lasting beyond the excitation. After cessation of luminescenceand renewed exposure to light, the material again absorbs light energyand exhibits the glow-in-the-dark property (anabsorbing-accumulating-emitting cycle). These are called afterglowphosphors—the glow after the excitation source is removed.

Various phosphorescent substances are known, including sulfides, metalaluminate oxides, silicates and various rare earth compounds(particularly rare earth oxides). The most common type of phosphorescentpigment is zinc sulfide structure with substitution of the zinc andactivation by various elemental activators. It is known that manyluminescent materials may be prepared by incorporating metallic zincsulfide (which emits green light). Moreover, with zinc sulfide amaterial or mixtures of materials variously termed activators,coactivators or compensators are usually employed. Known activatorsinclude such elements as copper (forming ZnS:Cu, probably the mostcommon zinc sulfide phosphor). Other sulfide phosphors which emitvarious colors of light include ZnCdS:Cu and ZnCdS:Ag, CaS:Bi, andCaSrS:Bi.

The other important class of long-life phosphorescent pigments is themetal aluminates, particularly the alkaline earth aluminate oxides, offormula MAl2O4 where M is a metal or mixture of metals. Examples arestrontium aluminum oxide (SrAl2O4), calcium aluminum oxide (CaAl2O4),barium aluminum oxide (BaAl2O4) and mixtures. These aluminate phosphors,with or without added magnesium, may be further activated with othermetals and rare earths. Alkaline earth metal aluminate oxide phosphorsand their preparation are discussed in pioneering research emanatingfrom Nemoto & Co., Ltd. (Murayama, et. al.; U.S. Pat. No. 5,424,006;issue date Jun. 1, 1995; priority date Apr. 28, 1993). As noted earlier,the importance of strontium in ceramic phosphors was apparent as earlyas 1942 to A. H. McKeag of General Electric Company. Most phosphorescentpigments suffer from the problems of low luminescence and/or shortafterglow.

Solid-state lighting is thought to be ultimately superior toincandescence, fluorescence, phosphorescence the lighting technologiesillustrated above.

General Background on Light Emitting Diodes

Solid state light emitting devices, including solid state lampsincluding LEDs are extremely useful because they potentially offer lowerfabrication costs, lower utilization costs with long term durabilitybenefits over conventional incandescent and fluorescent lamps. Due totheir long operation (burn) time and low power consumption, solid statelight emitting devices frequently are thought to provide a functionalcost benefit, even when their initial cost is greater than that ofconventional lamps. It is well known that because large scalesemiconductor manufacturing techniques can be used, many solid statelamps can be produced at extremely low cost. One such device is thesolid state light emitting diode (LED) which has in general lowfabrication costs, long operational lifetimes and low maintenance costs.For example, red light emitting diodes have been manufactured for over30 years and their operational lifetime is over ten years of continuousburn. Further, due to the highly advanced state of semiconductormanufacturing for red LEDs, these chromatic solid state lights areextremely inexpensive to manufacture. This highly advanced state of redLED manufacture benefits primarily from the fact that they are the firstchromatic LEDs to have been discovered and produced.

The traditional visible spectrum LED, it has been noted by many, resultsfrom the pioneering work of Nick Holonyak, Jr. who first began work onthe visible-spectrum light-emitting diode in 1960 while working atGeneral Electric. He was the first, reportedly in 1960, to growGaAs1-xPx (an alloy) and to construct visible-spectrum lasers and lightemitting diodes (seemingly in 1962). Holynak is the inventor of thefirst practical LED, the red GaAs1-xPx LED. Holynak had discovered thatthe wavelength of the GaAs diode (gallium arsenide) could be shiftedfrom the infrared to the visible spectrum by merely changing thechemical composition of the crystal itself to GaAsP (gallium arsenidephosphide).

Ten years later, M. George Craford invented the first yellow LED and 10times brighter red and red-orange LEDs, expanding the potential uses ofchromatic LEDs dramatically. He subsequently led the R&D efforts atHewlett-Packard.

In 1977, Russell Dupuis was the first to demonstrate that metal organicchemical vapor deposition (MOCVD) could be used to grow high-qualitysemiconductor thin films and devices, including LEDs. Today, the MOCVDmaterials technology is the most widely used method for the high-volumeproduction of LEDs worldwide.

The scientific achievements of Holonyak, Craford and Dupuis are renownedand reflect how scientific originality, imagination, innovativeness, andreduction to practice lead to commercial advances unimagined prior totheir creations. Light emitting diodes are now commercially available ina wide variety of designs and a plethora of manufacturing techniqueshave been developed. In addition to applications such as indicatorlights on home and consumer appliances, audio visual equipment,telecommunication devices and automotive instrument markings, such LEDshave found considerable application in indoor and outdoor informationaldisplays. But until the early 1990's, notwithstanding the outstandingand well recognized achievements of Holonyak, Craford and Dupuis, andthe legions of researchers advancing the art in academics, governmentlaboratories and commercial enterprises, commercial LEDs have producedlight only in the red, green or amber ranges and have not been generallysuitable for replacing, for example, incandescent bulbs, with normally awhite luminescence, in a wide variety of display applications.

General Background on Blue Light Emitting Diodes

For the longest time, blue LEDs were absent from the list of visiblelight LEDs. Pioneering work in the area of SiC and GaN semiconductors,as well as other materials, initiated and reduced to practice in thelate 1980's and early 1990's completed the visible light spectrum ofchromatic solid-state lights. The very earliest focus on GaNsemiconductors can be traced to gallium nitride “electroluminescent”diodes that were demonstrated at RCA Laboratories in the 1970s (J. I.Pankove, E. A. Miller, J. E. Berkeyheiser, RCA Rev. 32, 383 (1971)). Atleast three major problems had to be solved for GaNs to succeed: (i) thelack of suitable lattice-matched epitaxial substrates, (ii) thermalconvection problems due to the very high growth temperatures (about1000° C.), and (iii) the failure of p-type doping. Ultimately theseproblems were solved and today blue LEDs are sold in the billions ofunits per year and uv LEDs are also commercially available.

There are too many inventors and researchers of great importance andsubstantive contributions to reference herein, but considerable andsubstantive importance are the inventive work of Professor Isamu Akasakiof the School of Engineering, Nagoya University and Shuji Nakamura ofNichia Corporation. As it has been elsewhere reported (Faso, G. Science,Vol 272, Issue 5269, 1751-1752, 21 Jun. 1996), most work with GaN makesuse of sapphire substrates, which have a lattice mismatch of about 15%with respect to GaN. Akasaki at Nagoya University and Nakamura at Nichiaboth developed very similar buffer-layer technologies to achieve GaNepitaxial growth with appropriate defect density. Both Akasaki andNakamura use metal-organic chemical vapor deposition methods. Thesubstrate temperature is more than 1000° C. during growth. Thistemperature is exceptionally high and causes convection problems, whichwere addressed by one of Nakamura's inventions. He developed a dual-flowreactor, where an auxiliary stream of gas blows perpendicularly to thesubstrate, pushing the primary stream of reactants toward the substrateand improving the growth.

A long-standing problem was the failure to achieve p-type doping in GaNmaterials. Akasaki showed that a solution existed: he discovered thatlow-level electron beam irradiation could yield p-type GaN (H. Amano etal., J. Lumin. 40-41, 121 (1988)). Nakamura found (S. Nakamura, N.Iwasa, M. Senoh, T. Mukai, Jpn. J. Appl. Phys. 31, 1258 (1992)) thatmany previous GaN researchers had annealed their samples in ammonia(NH3). Ammonia dissociates above ˜500° C., releasing atomic hydrogen,which passivates the acceptors. Therefore, Nakamura switched toannealing in a clean nitrogen (N2) atmosphere and thereby invented areliable method to achieve high-quality p-type GaN materials. (1. Seealso Shuskus, A., U.S. Pat. No. 4,448,633, issued on May 15, 1984. 2.See also “Process for doping crystals of wide band gap semiconductors”U.S. Pat. No. 4,904,618 (and patents that reference same), inventorGertrude Newmark which proposes nitrogen as a “less mobile dopant” in awide band gap semiconductor.) These discoveries led Nakamura withcolleagues at Nichia to the development of commercial blue GaN LEDs (S.Nakamura, T. Mukai, M. Senoh, Jpn. J. Appl. Phys. 30, L1998 (1991)).

Relying on self-acclamations from Toyoda Gosei and Nichia, concurrentlywith the pioneering work reported from Nichia and as early as 1986,Toyoda Gosei started developing GaN-based Blue LEDs under the guidanceof Professor Isamu Akasaki and with the assistance of Toyota Central R&DLabs., Inc. In the following year, 1987, Japan Science and TechnologyCorporation supported the development of Blue LEDs to Toyoda Gosei,which Toyoda Gosei successfully achieved in 1991. In October 1995,Toyoda Gosei started commercial production of high-brightness Blue LEDs.

Shuji Nakamura and his efforts at Nichia are as legendary as theoutstanding science performed by Holynak, Craford and Dupuis. What isclear is that inventing and implementing blue light emitting diodes wasa breakthrough in materials science and electrical engineering.

Radiative recombination in GaN blue light-emitting diode die usingtime-resolved measurements show a bimolecular recombinationcharacteristic and at 300 K, a lifetime of 130 picoseconds. (C.-K. Sun,S. Keller, G. Wang, M. S. Minsky, J. E. Bowers, and S. P. DenBaars,“Radiative recombination lifetime measurements of InGaN single quantumwell”, Applied Physics Letters—Sep. 23, 1996—Volume 69, Issue 13, pp.1936-1938) These very short lifetimes are difficult to purposely quenchalthough trap states have been suggested to lead to yellow not blue oruv luminescence otherwise observed in GaN devices. (F. A. Ponce, D. P.Bour, W. Gotz, and P. J. Wright, Appl. Phys. Lett. 68, 57 1996. S.Christiansen, M. Albrecht, W. Dorsch, H. P. Strunk, C.Zanotti-Fregonara, G. Salviati, A. Pelzmann, M. Mayer, M. Kamp, and K.J. Ebeling, MRS Internet J. Nitride Semicond. Res. 1, 19-1997. S. J.Rosner, E. C. Carr, M. J. Ludowise, G. Girolami, and H. I. Erikson,Appl. Phys. Lett. 70, 420 1997. T. Sugahara, H. Sato, M. Hao, Y. Naoi,S. Kurai, S. Tottori, K. Yamashita, K. Nishino, L. T. Romano, and S.Sakai, Jpn. J. Appl. Phys., Part 2 37, L398 1998.) Moreover, Fe ions aregood quenchers. (M. Batentschuk, B. Schmitt, J. Schneider, A. Winnacker,“COLOR ENGINEERING OF GARNET BASED PHOSPHORS FOR LUMINESCENCE CONVERSIONLIGHT EMITTING DIODES (LUCOLEDs)”, Proceedings published as Volume 560of the Materials Research Society Symposium Proceedings Series. Apr. 6,1999) Rare earth ions doped in GaN have been shown to non-radiatively(and radiatively) transfer their energy to the GaN. Similarly, the GaNhost was photo-excited by 300 nm, 200 femto-second optical pulses, andthe energy transfer from the host to the 5D0 state of the Eu3+ ions wasdeduced to proceed through free and bound exciton trapped states with atemperature independent decay constant. (Lee. et. al.; “Temperaturedependence of energy transfer mechanisms in Eu-doped GaN”, Journal ofApplied Physics Vol. 95 No. 12, p 7717-7724, June 2004) It has beenproposed that rare earth doped GaN can be used to make indoor whitelights. (A. J. Steckl, R. Birkhahn and M. J. Garter, “Rare EarthLuminescence in GaN and Related Device Performance” Proceedingspublished as Volume 560 of the Materials Research Society SymposiumProceedings Series. Apr. 5, 1999.)

The Discovery of White Light Emitting Diodes

The introduction of blue and or ultraviolet LED, however, allows intheory for the introduction of white light LED systems and thus has thepotential to open the display market to LEDs by providing a practicalmeans to achieve vibrant color, pale color, and white light (achromaticlight without hue) illumination.

Given the desirability of solid-state white lights for generalillumination and for displays, considerable effort has been expended toproduce white light LEDs. Although the recent availability of the blueLED makes a full color, and by extension a white light displayrealizable, conventionally it has been considered that such a displaywould require at least three LEDs, at least one each of blue, green andred light emitting diode die. The multiple LEDs would be thenincorporated into complicated and expensive LED modules to obtain therequired broadband illumination necessary to provide white light. Evenif a discrete LED lamp were constructed that provides white illumination(as opposed to the utilization of a multitude of single die, singlecolor discrete LED lamps in a module or sub-assembly), prior to theinvention of Down-Conversion for white light generation, the state ofthe art required the utilization of multiple LED dies and typically atleast four electrical leads to power these dies. An issued United Statespatent teaches a variable color light emitting diode having a unitaryhousing of clear molded solid epoxy supporting three LED diescharacterized as producing color hues of red, green and blue,respectively. (Stinson, U.S. Pat. No. 4,992,704)

Attempts to make white light LED from a single die, which would provideconsiderable economic and performance advantage over Stinson became anearly concern in the development and enhancement of GaN semiconductors.For example, it was claimed [Mananbe et. al., Japanese Patent JP4010665,publication date 1992 Jan. 14; claims priority date of 1990 Apr. 27] “agallium nitride-based compound semiconductor light-emitting element isprovided with the following: an n-layer composed of an n-type galliumnitride-based compound semiconductor (Alx1Ga1-xN; including X=0); and ani-layer composed of an i-type gallium nitride-based compoundsemiconductor (AlxGa1-xN; including X=0). At the light-emitting element,zinc (Zn) and silicon (Si) are used as elements to be doped for thei-layer. When the i-layer is doped with only zinc, the emitted lightcolor of a light-emitting diode is a blue color. When the layer is dopedwith zinc and silicon and the doping amount of silicon is comparativelysmall at a ratio of 1/200 to 1/1000 to a zinc density, the emitted lightcolor of the light-emitting diode is a red color. When the ratio iscomparatively large at 1/100 to 1/200, the color is a white color.”These single die GaN complex doped devices failed to perform favorablyfor the generation of white light illumination.

A rather interesting example similar in spirit to the technologyreferenced in the immediately preceding paragraph was the observation ofYoshinori Shimizu that if a blue LED is used as a backlight in adisplay, and the display had a layer containing an orange fluorescingelement; the display appeared to be white. (Y. Shimizu, Japanese Patentnumber JP8007614, Jan. 12, 1996; Japanese Application numberJP19940134763, Jun. 17, 1994) However, the luminescent element and thelight-emitting diode lamp were not structurally related nor of the samestructure.

Discovery of Down-Conversion

Baretz et. al. [2003] taught the art of white light generation usingDown-Conversion. This is a fundamental process known also referred to asluminescence conversion and or phosphor LEDs and the art has beendramatically enhanced by the utility of this method of generating whitelight from a single light emitting diode die. Baretz et. al. [2003] inthe now issued U.S. Pat. No. 6,600,175 filed on 26 Mar. 1996 and issuedon 29 Jul. 2003 claimed the invention of white light using primaryradiation of a relatively shorter wavelength radiation and a collectionluminophoric medium arranged in receiving relationship to said primaryradiation, and which in exposure to said primary radiation, is excitedto responsively emit a secondary, relatively longer wavelength,polychromatic radiation, “with separate wavelengths of saidpolychromatic radiation mixing to produce a white light output.” Whitelight is known to be defined as achromatic light that is light with nohue. Many invoke the term pure white to refer to achromatic light. Theterm “white light” is not explicitly defined in Baretz et. al. [2003]although the specification states the purpose of the invention is to“provide while (sic) light solid state luminescent devices using asingle die, which initially provide monochromatic radiation and whereinthe monochromatic radiation is converted to polychromatic white light,thus providing a solid state illumination device with whiteilluminance.” Hence, the specification teaches that white light ispracticed as polychromatic and that which provides white illuminance.There is an important difference between luminance and illuminance eventhough that which is usually reported is the former: the latterindicates the light that falls on a surface. The point is that a lightthat has white luminance—appears white at the source of the light—maynot be white light when falling upon a surface (such as a desk, a wallor a floor); further, light that has white illuminance need not be whiteat the source of the light. For example, three spatially separatecolored LED lamps may appear white only on the surface of interest ifjust prior to falling on the surface of interest—the surface one isseeking to illuminate—the three discrete, distinct, and separate colorsare mixed. Later on, the patent also specifies the opposite: “It will beapparent . . . to a luminophoric medium which down-converts the appliedradiation to yield a white light emission from the luminophoric medium”;that is a white light emission from the surface of the device itself ifthe device itself comprises a luminophoric medium, which indeed it does.Hence the specification of Baretz et. al. [2003] teaches both whiteluminance and white illuminance.

Note that many have defined polychromatic light as: 1. [adj] (of lightor other electromagnetic radiation) composed of more than onewavelength; “polychromatic light”; 2. [adj] having or exhibiting manycolors. Light consisting of a single wavelength or a very narrow band ofwavelengths is known as monochromatic light (this is a spectraldefinition); others have defined monochromatic light as all the hues andshades of a single color light (this is a colorimetric definition). Mostlight sources are not pure spectral sources; rather they are createdfrom mixtures of various wavelengths and intensities of light. To thehuman eye, however, there is a wide class of mixed-spectrum light thatis perceived the same as a pure spectral color. Orange light in spectralspace is at a fixed wavelength of around 600 nm. However, orange canalso be perceived if a device is emitting a mixture of about two partsred to one part green light. We cannot see the difference, and thereason has to do with the pigments that make up our color vision cells.A useful quantification of this property is the dominant wavelength,which matches a wavelength of spectral light to a non-spectral sourcethat evokes the same color perception. Dominant wavelength is the formalbackground for the popular concept of hue. In addition to the many lightsources that can appear to be pure spectral colors but are actuallymixtures, there are many color perceptions that by definition cannot bepure spectral colors due to desaturation or because they are purples(which do not appear in the Newtonian pure spectrum). Some examples ofnecessarily non-spectral colors are the achromatic colors (black, grayand white) and other colors such as pink, tan and magenta. Hence,defining light in terms of colors is extremely problematic.

Prior to the invention of down-conversion in solid-state lighting,up-conversion in solid-state lighting had been known. (W. H.Grodkiewicz, et. al; U.S. Pat. No. 3,659,136, issue date Apr. 25, 1972)In contrast to up-conversion, which requires multi-photon absorption andhence is observed and useful to wavelength convert lasers,down-conversion is energetically downhill and hence a single photon canbe down-converted, does not require multi-photon absorption and canoccur in lighting sources with intensity considerably less than thatobserved with lasers. Down-conversion leads to a significant Stokesshift (bathochromic shift); the challenge in down-conversion in asolid-state p-n junction is not to demonstrate a Stokes shift but ratherto generate white light. In assemblies of multiple luminophors, thechallenge is to prevent all of the luminescent elements from acting asquenchers so that all of the light is not down-shifted to the lowestenergy emitter (e.g.; a red emitter in a mixture of red, green and blueluminophors). Down-conversion and the subsequent filing of phosphor LEDs(WO9748138, EP0856202 (A3), U.S. Pat. No. 5,813,752, and related patentapplications) and luminescence conversion (U.S. Pat. No. 6,576,930 andrelated patents and patent application) invoke radiative energy transferas the means of transferring energy from the single light emitting diodedie, capable of generating only monochromatic light, to a luminescentelement that generate polychromatic light. Hence, heretofore,down-conversion, luminescence conversion and phosphor LEDs, have allinvoked and been exclusively limited to radiative energy transfer. Ithas not been heretofore accepted that the radiative energy transfer mayoccur not only from primary emission emanating from the p-n junction ofthe light emitting diode die to a plethora of secondary luminophors, butalso from a luminophor of higher energy to a luminophor of lower energyas known in other types of illumination technologies. (General ElectricCompany, Great Britain Patent number GB448887; issue date Jun. 17, 1936)

Radiative energy transfer is one of many different mechanisms for thetransfer of energy from the excited state of a donor, thereby formingthe ground state of the donor, to the ground state of the acceptor, inso doing forming the excited state of the acceptor. In the case of a p-njunction, the donor is the state (presumablye an excited state) of ahole:electron pair at the junction itself. Radiative energy transfer isalso called trivial energy transfer and is formally defined as thetransfer of excitation energy by radiative deactivation of a donormolecular entity and re-absorption of the emitted light by an acceptormolecular entity. The IUPAC Compendium of Chemical Terminology 2ndEdition (1997) defines the probability of radiative energy transfer,Pr,t, as:

where J is the spectral overlap integral, [A] is the concentration ofthe acceptor, and d□ is the specimen thickness. This type of energytransfer depends on the shape and size of the vessel utilized. Othermeans for energy transfer are Forster energy transfer and Dexter energytransfer which are typically referred to as non-radiative energytransfer. The spectral overlap term has led to the expansive research ofnew phosphors for solid-state lighting whereas the spectral overlapbetween Hg emission and existing fluorescent tube lighting phosphors isvery high.

Forster energy transfer is a mechanism of excitation transfer that canoccur between molecular entities separated by distances considerablyexceeding the sum of their van der Waals radii. The rate of Forsterenergy transfer is directly proportional to the square of an orientationfactor and the spectral overlap integral J, and inversely proportionalto the refractive index of the medium to the fourth power, the radiativelifetime of the donor, and r the distance between donor (D) and acceptor(A) to the sixth power. The critical quenching radius, r0, is thatdistance at which the rate of Forster energy transfer is equal to theinverse of the radiative lifetime. Forster energy transfer is describedin terms of an interaction between the transition dipole moments (adipolar mechanism) of the donor and acceptor molecules. (For an exampleof Forster Energy Transfer in organic light-emitting diodes, seeO'Brien, et. al., Canadian Patent Application CA 2448514)

Dexter energy transfer is an energy transfer mechanism that occurs as aas a result of an electron exchange mechanism. It requires an overlap ofthe wave functions of the energy donor and the energy acceptor. It isthe dominant mechanism in triplet-triplet energy transfer. As withradiative energy transfer and Forster energy transfer, the rate ofDexter energy transfer is proportional to J, the spectral overlapintegral. It is also proportional to exp-2r, where r is the distancebetween the donor and acceptor. (Dexter, D. L., J. Chem. Phys. 21:836(1953))

Energy transfer via forbidden transitions is allowed by exchangeinteractions while they are much less probable in the Forster mechanism.Energy will be transferred mainly by the Forster mechanism unless r isless than 10 angstroms. (D. R. Walt, U.S. Pat. No. 5,254,477; Oct. 19,1993)

From the theoretical treatment there are two critical parameters thatimpinge upon the energy transfer efficiency-inter-molecular distance andspectral overlap. The fixed distance requirement constrains the“otherwise fluorescent” donor and the absorbing acceptor to begeometrically positioned within a defined range for energy transfer tooccur. For Forster transfer, a distance between 10 and 100 Angstroms isessential. At greater distances, the energy transfer efficiency isessentially zero. Below 10 Angstroms, the Dexter transfer mechanismcomes into play. The Dexter mechanism also enables efficient energytransfer to occur. When the distance is decreased to 5 Angstroms, thetransfer efficiency approaches 100% and further decreases in distanceare not observable as changes in fluorescence emission intensity.

Spectral overlap is essential to energy transfer. Without finiteoverlap, non-radiative energy transfer does not occur. The greater theoverlap between the donor's emission and the acceptor's absorptionspectrum, the greater the transfer efficiency. Accordingly, the spatialdistance and spectral overlap requirements are related. As spectraloverlap becomes greater, the distance requirement may be relaxed.Conversely, as the degree of spectral overlap decreases, it is importantthat the fixed spatial distance be small for efficient non-radiativeenergy transfer to occur. Thus, the donor acceptor conjugate mustprovide a spacial relationship between 5 and 100 Angstroms as well as afinite spectral overlap between the fluorophore and absorber species.

Another mechanism of quenching is through electron transfer. Forexample, the photoluminescence of CdSe quantum dots in aqueous media hasbeen studied in the presence of gold nanoparticles with differentshapes: the steady state photoluminescence intensity of CdSe quantumdots (1.5-2 nm in size) is quenched in the presence of goldnanoparticles and a decrease in the lifetime of the emitting states ofCdSe quantum dots in the presence of quenchers. It was found that thequenching rate of surfactant-capped gold nanorods—as thenanoparticles—decreases as the length of the nanorods decreases,although the overlap between the CdSe emission and the nanorodsabsorption increases. This suggests that the quenching is a result ofelectron transfer rather than long-range (Forster-type) energy transferprocesses. The quenching was attributed to the transfer of electron withenergies below the Fermi level of gold to the trap holes of CdSe QD.(Nikoobakht B, Burda C, Braun M, Hun M, EI-Sayed M A, “The quenching ofCdSe quantum dots photoluminescence by gold nanoparticles in solution.”,Photochem Photobiol. 2002 June; 75(6):591-7; see also Diana Lynne Bull,A STUDY OF FLUORESCENT NANOPARTICLES: QUANTUM DOTS AND SILICA DOTS: AThesis Presented to the Faculty of the Graduate School of CornellUniversity In Partial Fulfillment of the Requirements for the Degree ofMaster of Science, August 2004; see also for rare earths and excitontrap states (energy transfer in GaN films doped with rare earth ions),see A. J. Steckl et al. Compound Semiconductor 2000 6(1) 48)

One skilled in the art can see that there are a variety of means in downconversion systems by which the acceptor molecule that emits secondaryradiation systems can be populated into their excited states, subsequentto which useful and desirable photons are generated that appears to theobserver to be achromatic, white light or chromatic light. Non-radiativeenergy transfer can occur between emitters of secondary radiation (H. W.Leverenz, Canadian Patent Number CA 507420, issue date Nov. 16, 1954; H.W. Leverenz, Canadian Patent Number CA 470923, issue date Jan. 16, 1951)and between the excited states that defines the p-n junction with theemitter of secondary radiation. Praseodymium luminescent centers arepopulated into their excited states apparently by non-radiative energytransfer from the excited state that defines the GaN p-n junction: “ . .. Pr in GaN can be effectively excited by forward bias p-n junction endutilized in LED . . . ”. (H. J. Lozykowski, W. M. Jadwisienczak, and I.Brown “Photoluminescence and Cathodoluminescence of GaN doped with Pr”MRS Internet J. Nitride Semicond. Res. 5S1, W11.64 (2000).)

However, it is also desirable for the purposes of general illuminationto have light of a pale color that is chromatic light with hue. Thispale color light is frequently referred to by its color-rendering indexand or color temperature. Since white light is achromatic, it has nocolor—that is no hue. This is an essential element of fact for whitelight—no color; hence, all chromatic light may approach white light, butis not, in fact white light. Where chromatic light ends and achromaticlight begins can only be defined by a more complete set ofspecifications than is normally discussed; in many cases, the inventorreverts to specifications using the terms color temperature and colorcorrelated index to more completely describe their invention.

It would be desirable therefore, to produce pale color light for generalillumination also using down-conversion. This desirability of asolid-state light using one light emitting diode die to effectdown-conversion and the generation of “color” light was also taught withthe disclosure of Baretz et. al. [2003]. Pale color light, color lightapproaching white but light which is not achromatic, was taught by thedisclosure of Baretz et. al. [2003]. Regardless of whether the light soproduced is chromatic or achromatic, the mechanism taught by Baretz et.al. [2003] is the same. They also showed how organic and inorganicluminophors down-convert the primary radiation from the light emittingdiode die or non-identical light emitting diode dies into secondaryradiation of more useful content or specification.

In one embodiment, Baretz et. al. [2003] describe a down-convertingmaterial with three organic dyes: a blue fluorescer (Lumogen® F Violet570—a substituted naphthalene-tetracarboxylic diimide), a green-yellowfluorescer (Lumogen® F Yellow 083—substituted perylenetetra-carboxylicdiimide) and a red fluorescer (Lumogen® F Red 300—a substitutedperylenetetracarboxylic diimide). Baretz et. al. [2003] claim in thisembodiment a composition comprising such blue, green-yellow, and redfluorescent materials, all organic based, and incorporated in aninsulating epoxy polymer. Based on the specification disclosed by Baretzet. al. [2003], the three aforementioned Lumogen® dyes are individualexcited by primary radiation from the p-n junction of the light emittingdiode die or if more than one light emitting diode die, the plurality ofthe light emitting die must have the same wavelength. Others havereferred to the ability of organic luminophors to down-convert primaryradiation from LEDs with a p-n junction to polychromatic radiation; anearly patent discusses putting fluorescers in the epoxy envelopeencapsulating a light emitting diode die but not to generate white lightwhich is inherently more difficult to accomplish. (1. Nakamura et. al.;Japanese Patent Number JP5152609, issue date Jun. 18, 1993; 2. P.Schlotter, et. al.; Materials Science and Engineering B59 (1999)390-394; 3. U. Kaufmann, et. al.; “Single Chip White LEDs”, physicastatus solidi, Volume 192, Issue 2, Pages 246-253, Published Online: 12Jul. 2002, Wiley-VCH Verlag Berlin GmbH, Fed. Rep. of Germany)

It is a well known principle of excited state quenching that multiplequenchers if simultaneously present will ultimately find the lowestenergy emitter. Hence, in the presence of blue, green and redfluorescers which are populated by a variety of radiative and ornon-radiative means, but each of which may act as quenchers may findthemselves to exclusively populate—in a final state of equilibrium whereno other quenching is to take place, only the excited state of the redfluorescer. Hence, the simultaneous presence of blue, green and redfluorescers—all of which have spectral overlap that may afford Forsterenergy transfer to take place, for example—may only lead to red lightemission. In the case of Baretz et. al. [2003], however, it wasrecognized that certain factors may take place—including extremely shortradiative lifetimes and the dispersement of luminophoric centers—thatmay avoid the well known quenching to the lowest energy emitter.Alternatively, as it has been demonstrated elsewhere, where only oneluminophor is present in a white phosphor LED (such as one with a blueLED die and a yellow phosphor), quenching to the lowest energy emitteris not a problem nor contemplated since only one luminophoric dye ispresent in the system. Hence, the invention of Baretz et. al. [2003]teaches radiative down-conversion for single phosphor luminescenceconversion, but also down-conversion in so called RGB phosphor LEDs(that is, lamps with red, green and blue phosphors).

One advantage of luminophors with short radiative lifetimes as discussedin the preceding paragraph are that the rate of luminescence,essentially the reciprocal of the lifetime, is extremely fast. It hasbeen observed and commented on by others investigating the phenomenonknown as down conversion and invented by Baretz et. al. [2003] that withhigh photon flux of the primary radiation, there is essentially asaturation effect so that no more secondary radiation is produced andmore primary radiation is emitted. In the specific case of a blue LEDdie, the phenomenon that has been observed is that as the electricalload is increased—which requires robust p-n junctions—more blue light isemitted and proportionally less white light is emitted. The problem thathas not been heretofore recognized is that with fast rates ofluminescence from the excited states, these excited states can notabsorb a secondary photon, assuming of course that the absorptionspectrum of the first excited state of the down converting luminophoroverlaps the spectral characteristics of the primary radiation. Withlower rates of luminescence, multiple photon events are more likely tooccur; however, with low rates of luminescence, mechanisms, such asexcited state degradation, become competitive thereby effecting theinstantaneous and long term performance of the underlying system. Itwould be desirable therefore for a device where low rates ofluminescence are not problematic and where the device constructionitself will mitigate and or eliminate these degradation mechanisms inthe excited state (or in the ground state which may also occur, butgenerally with a lower rate).

The invention of Baretz et. al. [2003] is not limited to anyoneparticular semiconductor although the claims of the issued patent arelimited to white light and at least one semiconductor die with the sameprimary radiative wavelengths; more recently down conversion is claimedin an organic light emitting diode, that is a solid-state light withouta semiconductor p-n junction. (Duggal et. al., U.S. Pat. No. 6,700,322)

While Baretz, et. al. [2003] taught that both organic fluorescers andinorganic phosphors can be used for down-conversion to generate whitelight (as well as chromatic light), the teachings subsequent to theinvention of Baretz et. al. [2003] and prior to this invention beingclaimed herein have focused on inorganic phosphors frequently referredto as ceramic phosphors. Ceramic phosphors utilized in solid-statelighting are not all that different from the phosphors previouslydiscussed and used for fluorescent lighting and CRT emission. The majorchallenge for ceramic phosphors utilized in down conversion is that thelight emission—the primary radiation—from the diode die are narrow,usually singular in range and of wavelengths of considerably lowerenergy than that absorbed by CRT and fluorescent lamp phosphors and thatthe narrow emission profile from the p-n junction has poor overlap withthe excitation spectra of the ceramic phosphors required to effect downconversion.

For example, blue light emitting diode die typically emit—within anarrow 5 nm band pass—at 430 nm through 470 nm, depending on thematerial composition of the die active layer. The ceramic phosphor Cedoped yttrium aluminum garnet absorbs blue radiation reasonably well andemits in the yellow. Nevertheless, the primary radiation is partiallyemitted (incomplete absorption of the primary radiation) and hence thecolor rendering index is not optimal. On the other hand, uv LED dietypically emit—within a narrow 5 nm band pass—at 340 nm through 390 nm,depending on the material composition of the die active layer with mostnearer 380 and 390 nm. Unfortunately, most ceramic phosphors that aresaid to be excited by uv radiation do not absorb substantively between340 nm through 390 nm although many are known that absorb uv light froma mercury vapor lamp. For example, whereas a typical mercury vapor lamphas multiple line emissions from the excited states of mercury, thesemultiple lines are of relatively high energy (254 nm, 313 nm, 365 nm).Most of the phosphors used in other applications do not absorb in theregion presently required in solid-state lighting implementations with asemiconductor p-n junction although some have utility: as the bluecomponent, BaMgAl10O17:Eu2+ or ZnS:Ag+ are known as inorganic phosphors;ZnS:Cu+ or (Zn, Cd)S:Cu+, or ZnS: (Al, Cu)+ are known as blue-greencomponent; Y202S:Eu2+ is known as red component. (Jermann, et. al.;United States Patent Application US2004056256; publication date Mar. 25,2004) Jermann et. al. describe a white light LED lamp using a bluephosphor ZnS:Ag+; using a green phosphor ZnS:Cu+, Al+ where Cu and Alare used together; and using a red phosphor ZnS:Cu+, Mn+, where Cu andMn are used together. The green phosphor in the formulation of Jermannet. al. may alternatively be SrAl2O4:Eu2+. See for example phosphorssold and marketed by Honeywell Specialty Chemicals Seelze GmbH which aregenerally excited by uv light in between 340 nm through 390 nm.

Fluroescent and Phosphorescent Down Conversion Materials Specific forLEDs

As noted earlier, the major challenge for ceramic phosphors utilized inLED down conversion is that the light emission—the primaryradiation—from the diode die are narrow, usually singular in range andof wavelengths of considerably lower energy than that absorbed by CRTand fluorescent lamp phosphors and that the narrow emission profile fromthe p-n junction has poor overlap with the excitation spectra of theceramic phosphors required to effect down conversion. Hence, materialsdifferent than that used in fluorescent tube lighting is required toperfect LED down-conversion.

Fluorescence and materials that fluoresce involves light emissionwithout a change in spin multiplicity. Phosphorescence and materialsthat phosphoresce involves light emission with a change in multiplicity.Materials that fluoresce are called fluorescers or fluorophors;materials that phosphoresce are called phosphors or more specifically,if the term phosphor is unclear, phosphorescent phosphors. Because stateto state transitions that require a change in spin multiplicity have aslower rate of transition, phosphors (e.g.; triplet states thatphosphoresce) typically have long lifetimes. State to state transitionsthat do not require a change in spin multiplicity have a faster rate oftransition; hence fluorophors typically have short excited statelifetimes. The longer the lifetime, the more probably an alternativeevent such as quenching may occur. Phosphorescence therefore is notexpected to be a beneficial phenomenon in systems where quenchers, suchas water and or oxygen may exist, unless there is a mechanism forspeeding the rate of change in spin multiplicity. Spin-orbit coupling issuch a mechanism and heavy elements, such as those elements found inceramics, have spin-orbit coupling of sizeable magnitude. In thesecases, ceramic phosphors may have a reasonably short excited statelifetime as the rate of the radiative transition is enhanced throughspin-orbit coupling. As a result, phosphors may be as efficient asfluorophors in the yield of luminescence from their respective excitedstates. Nevertheless, it is desirable to have solid-state lightingdevices where the performance of the down conversion system is not ruledby the lifetime of the selected luminophor for reasons already cited.Other than enhancing the rate of luminescence, the only other means ofaccomplishing the desirability mentioned in the preceding sentence is tomake competing processes less likely, a formidable chore, neverthelessone that this present invention addresses.

It has been reported that a near-UV light-emitting diode could be usedas a primary light source to irradiate films of red, green and bluepowdered “fluors” dispersed on the surface of a glass slide. (Sato, et.al. Japanese Journal of Applied Physics, Vol. 35 (1996) L838-L839;received 27 Mar. 1996; accepted 16 May 1996; published 1 Jul. 1996.Title of reference: “Full-Color Fluorescent Display Devices Using aNear-UV Light-Emitting Diode.”] With said configuration, the “fluors” soirradiated produce the primary colors of red, green or blue and “whitecolor” is easily obtained. The fluors used by Sato, et. al., wereinorganic materials ZnS:Ag (blue), ZnS:Cu,Al (green) and ZnCdS:Ag (red)and the fluors were dispersed in aqueous solutions of polyvinyl alcoholand spin-coated onto the glass slides. The glass slides were used tosimulate a display and to prove that near-UV light-emitting diodes couldbe used to power said display through radiative energy transfer. Theterm fluor may have been used to mean a transparent or translucentmineral of different colors as opposed to addressing the multiplicity ofthe luminescent state. More recently, it has been taught that a stablewhite light LED “with InGaN-LED that generates a blue color of 410nm-460 nm to excite the ZnSSe fluorescent screen by the blue so as togenerate a yellow color, and then the blue and the yellow generated aresynthesized into a white color.” (Fujiwara, Japanese Patent ApplicationJP2003347588; filed 2003 Dec. 5; claims priority date of 2002 May 28)

Exemplary devices have been developed for the purpose of enhancing downconversion: it has been disclosed of a light emitting device for use inlighting and/or display applications which includes a UV/blue LEDlocated in a depression having reflecting sidewalls, a lighttransmitting material surrounding the LED and filling the depression,and a “phosphor” more specifically “particles of a visible lightemitting phosphor surrounding the sides and top of the LED”. (Vreins,et. al.; U.S. Pat. No. 5,813,753; issue date Sep. 29, 1998, filed on:May 27, 1997, claims priority date from U.S. patent application Ser. No.08/661,520, filed Jun. 11, 1996; issued on Sep. 29, 1998) Vreins, et.al. (1998) do not define nor specify a phosphor but, by virtue of claimsin a co-pending application the phosphor is “UV and blue excitable,visible light emitting.” (Ronda, et. al., U.S. Pat. No. 5,813,752,issued Sep. 29, 1998). Vriens et. al. (1998) do not claim white light byvirtue of down-conversion although their device is one thatdown-converts as the particles of phosphors are excited by uv and bluelight and then emit visible light as a result. In the European patentemanating from the same disclosure white light is also not claimed nor,in either case, were the inventors able to demonstrate that white lightis achievable with their system. (Stanton, et. al., European PatentEP0856202, issue date Aug. 5, 1998)

In an excellent series of work but nevertheless one filed after theinvention of Baretz et. al. [2003], Reeh, et. al. disclosed alight-radiating semiconductor component which has a radiation-emittingsemiconductor body and a luminescence conversion element. (Reeh, et.al.; U.S. Pat. No. 6,576,930 (assignee: Osram; filed on 7 Dec. 2000;claims priority date of Jun. 26, 1996[DE] 196 25 622 and Sep. 20,1996[DE] 196 38 667; issued on 10 Jun. 2003) The invention of Reeh, et.al. appears to have been the work of researchers from FraunhoferInstitute for Applied Solid State Physics and which, by virtue of thepatent filing, and evidenced in subsequent documentation filed with theUnited States International Trade Commission assigned to Osram OptoSemiconductors, a unit of Osram, itself a subsidiary of Siemens. Thesemiconductor body emits radiation in the ultraviolet, blue and/or greenspectral region and the luminescence conversion element converts aportion of the radiation into radiation of a longer wavelength. Thismakes it possible to produce light-emitting diodes which radiatepolychromatic light, which appears as white light, with only a singlelight-emitting semiconductor body. The difference between achromaticlight and polychromatic light is not addressed in the specification ofReeh et. al.

A particularly preferred luminescence conversion dye is YAG:Ce, a ceriumdoped yttrium aluminum garnet. [A substitute ceramic phosphor that maybe used—not discussed by Reeh et. al.—as an alternative isY3(Al1-sGas)5O12:Ce:XBaAl2O4 where s=0 and x=1.0 and where said phosphormay show considerable barium composition in the elemental spectralpatterns.]

The invention of Reeh et. al. has the undesirable specification, claimand element that the white light so produced, achromatic light without ahue, contains a portion of the original radiation in the ultraviolet, ifthe original semiconductor body emits radiation in the ultraviolet. Itis an undesirable element in that the ultraviolet light emanating fromthe semiconductor light may be a safety hazard to the observers of thewhite light. It would be desirable to not require the light so producedto contain a portion of the original radiation; my present invention hasthat desirable feature as will be more fully described herein. Asevident within claim 4 of U.S. Pat. No. 6,576,930 by Reeh et. al, theinvention is based on “a luminescence conversion element with at leastone luminescent material, said luminescence conversion element beingdeposited on said semiconductor body, said luminescence conversionelement converting a radiation originating in the first wavelength rangeinto radiation of a second wavelength range different from the firstwavelength range, such that the semiconductor component emitspolychromatic visible light comprising radiation of the first wavelengthrange and radiation of the second wavelength range.” For a white lightpowered by a blue light-emitting diode die, the invention requires“radiation of the first wavelength range” and “radiation of the secondwavelength range” where the latter requires excitation into the excitedstate by radiative energy transfer from the former and where theluminescence conversion element is deposited on the semiconductor body.It is generally not appreciated and recognized by those with skills inthe art that for achromatic light powered by a blue LED die as opposedto polychromatic light powered by the same blue LED die, the bluecomponent needs to be changed so as to parallel the photopic response inthe blue region as closely as possible; therefore, it is desirable thatthe radiation of the first wavelength range be altered such that theblue component be distorted not only by radiative energy transfer (whichonly alters the quantity of the radiation of the first wavelength range)but also by spectral filtration (such that the radiation of the firstwavelength range is in fact not at all part of the product's emissionprofile).

My present invention also does not require the luminescence conversionelement to be deposited on the semiconductor body and in fact it ispreferred that the luminescence body is not deposited on thesemiconductor body as will be claimed specifically. It is also the casethat whereas the aforementioned claim of Reeh et. al. is contingent on“semiconductor component emits polychromatic radiation”, an extremelyunlikely event in that semiconductor components emit narrow bandchromatic radiation all would agree, in the case of my invention thesemiconductor body may emit monochromatic and or a mono-coloredradiation although the device of my invention that includes asemiconductor component may emit chromatic or achromatic radiationsubsequently thereto. In certain implementations, where theconcentration of the luminescent element is high enough, the radiationof the first wavelength can not be delivered in an unaltered state as bythe definition of radiative energy transfer, the photons of the firstradiative range are absorbed by the luminescent element and not everywavelength is absorbed with equal extinction coefficient. Hence thespecification of Reeh et. al. is difficult to practice since radiativeenergy transfer, by definition absorbs—does not transmit—photons of theprimary radiation range thereby altering quantitatively andqualitatively the primary radiation range.

As noted before, the invention of Reeh et. al. claiming a priority dateafter the filing of Baretz et. al. [2003] uses the term luminescenceconversion to refer to using phosphors to emit chromatic and achromaticlight. Luminescence conversion is detailed in various reports emanatingfrom the aforementioned Fraunhofer Institute. For example, one report in1997 states “Single white LEDs were not feasible to date, as they emitmonochromatic light only. The mixture of colors making up white lightwas only possible with a combination of three different diodes.Researchers at the Fraunhofer-Institute fOr Angewandte FestkorperphysikIAF (Fraunhofer Institute for Applied Solid State Physics) have achieveda breakthrough. The innovative idea was the generation of white light byluminescence conversion. Blue emitting diodes based on gallium nitridewere combined with luminescent dyes giving bright light emission atchanged wavelengths. The resulting mixture of colors is visible as whitelight. Furthermore, these LUCOLEDs—luminescence conversion LEDs—allowlight emission in a wide color range, depending on the emission of thedyes used. In addition to white light, arbitrary color tones of thespectrum are possible, e.g. purple.” [January 1997 “Research News”published by Fraunhofer-Gesellschaft.]

In a press release on Apr. 23, 1999, the same Fraunhofer-Gesellschaftreported “Although red, green and yellowish-green LEDs have been on themarket for quite a long time, white light-emitting diodes could only beproduced by combining different colored LEDs. But two years ago researchscientists at the Fraunhofer Institute for Applied Solid State Physics(IAF) in Freiburg solved the problem—concurrently with Japanesescientists—by developing white light-emitting luminescence conversionLEDs. Pumped by a primary light source, luminescent materials like dyesor phosphors emit light at longer wavelengths by luminescencedown-conversion. To develop white light-emitting diodes, the IAF teamcombined blue light-emitting LEDs based on gallium nitride with organicor inorganic luminescent materials emitting in the yellow spectralrange. Mixing the blue radiation of the LED with the complementaryyellow light of the luminescent material results in a whitelight-emitting LED. By varying the concentration of the dye, the hue canbe changed easily. Thus small LEDs open up completely new opportunitiesin lighting design. The process for manufacturing white LEDs is simple:Yellow-emitting luminescent materials are mixed with epoxy resin andapplied to the blue-emitting diode. Osram Optic Semiconductors, asubsidiary of Siemens, has been mass producing them since last year.White LEDs are already used as standard equipment in the Audi TT sportscar. The innovative, simple, and inexpensive manufacture of the diodesis excellently suited for large volume production. Siemens willintroduce the first white LUCOLEDs commercially next year.” (1. See forexample, later discussions in S. Müller, R. Quay, F. Sommer, F.Vollrath, R. Kiefer, K. Köhler, J. Wagner; Fraunhofer-Institut fürAngewandte Festkorperphysik, Tullastrasse 72, 79108 Freiburg, Germany,“Epitaxial growth and device fabrication of GaN based electronic andoptoelectronic Structures”; 10th European Workshop on MOVPE, Lecce(Italy) 8-11 Jun. 2003. 2. P Schlotter, R Schmitt, J Schneider“Luminescence conversion of blue light emitting diodes”, Applied PhysicsA 64, 417 (1997).)

The Yellow-Emitting Ceramic Phosphor Ce-doped Yttrium Aluminum Garnetand The Formation of White Light from Blue and Complementary YellowDown-Conversion.

Nichia Corporation, as noted earlier, through the efforts of Nakamuraand his colleagues, self-claim that they started developing Blue LEDs in1989, and built up the technology for industrialization of GaN-basedBlue LEDs in 1991. The self-acclamation proffered by Nichia continueswith the comments “Nichia Corporation succeeded in the commercialproduction of high-brightness Blue LEDs in November 1993. Further, byapplying its expertise as a phosphor manufacturer, and by combining YAG(Yttrium Aluminum Garnet) phosphors, specifically Y3Al5O12:Ce3+ withBlue LEDs and, according to their own acclaim, Nichia Corporationstarted commercial production of White LEDs in 1996 for the first timein the world.” (“A New Phosphor for Frying-Spot Cathode-Ray Tubes forColor Television: Yellow-Emitting Y3A15O12:Ce3+”, G. Glasse et al.,Applied Physics Letters, vol. 11, No. 2, pp. 53-54 (1967)

Nichia's research and commercial efforts on white light LEDs aredocumented and detailed: the self-asserted operable United States patentis of inventor Yoshinori Shimizu. (Demand for Jury Trial: Nichia vs.Sharper Image; United States District Court Northern District ofCalifornia Case Number: C04-1360. Also, “Report on the filing ordetermination of an action regarding a patent or trademark”; TO:Commissioner of Patents and Trademarks; Washington, D.C. 20231; InCompliance with 35 § 290 and/or 15 U.S.C. § 1116 you are hereby advisedthat a court action has been filed in the U.S. District Court NorthernDistrict of California; Y. Shimizu, U.S. Pat. No. 5,998,925, issue dateDec. 7, 1999) Additional relevant information on U.S. Pat. No. 5,998,925to aid the review of the related prior art is: assignee: Nichia; filedon Jul. 29, 1997; claims priority date of Jul. 29, 1996[JP] 8-198585;Sep. 17, 1996[JP] 8-244339; Sep. 18, 1996[JP] 8-245381; Dec. 27,1996[JP] 8-359004; Mar. 31, 1997[JP] 9-081010. Shimizu, et. al. (1999)claim a light emitting device, comprising a light emitting component anda phosphor capable of absorbing a part of light emitted by the lightemitting component and emitting light of wavelength different from thatof the absorbed light; wherein said light emitting component comprises anitride compound semiconductor represented by the formula: InGaAlN andsaid phosphor contains a garnet fluorescent material comprising 1) atleast one element selected from the group consisting of Y, Lu, Se, La,Gd and Sm, and 2) at least one element selected from the groupconsisting of Al, Ga and In, and being activated with cerium.

Shimizu argue that the primary purpose of their invention is to overcomeeither: for inorganic luminophors, degradation of the phosphor due toprecipitation of the metal component or a change in properties of themetal component leads to discoloration; in the case of an organicluminophor, coloration occurs due to breakage of the double bond. It wassupplementary advanced that degradation may occur from localized heatingand or moisture. There has been a long unmet need to overcome thesedeficiencies for a wide class of luminophors. Further, in the case of anorganic luminophor that is charged (ionic), the localized electric fieldmay cause electrophoresis which may cause an undesired change in colortone. Simizu focused on selecting a very narrow class of luminophorsthat may overcome the aforementioned challenges and highlighted two:cerium doped yttrium aluminum garnet and cerium doped gadolinium indiumgarnet. Shimizu also argues that it is preferable for the LED to emitblue light, as opposed to uv light, since the latter will degrade theresin. (Shimizu, et. al.; 1999) However, in the absence of thedegradation of the resin, one of ordinary skill in the art willrecognize that it is preferable to have the LED emit uv light as opposedto blue light since more luminophors absorb light in the uv than they doin the blue. However, the most important reason not to prefer blue to uvlight for the LED is that the blue light from the LED die willinevitably contribute substantively to the chromaticity of the intendedachromatic light therefore making the light not achromatic. Moreimportantly, even in the very unlikely and heretofore not realized eventthat if the light appears to be achromatic at zero time, it isinevitably the case, as the device ages that the blue component willbecome more substantial as it is the primary radiation in the device ofShimizu. As noted earlier, high photon fluxes of blue light willinevitably increase blue component to the polychromatic irradiation dueto saturation of the down-conversion process. Therefore it is preferred,if achromatic light is to be generated, at zero time and throughout theuseful light of the device, that a non-visible component be at the veryleast an element of the primary radiation.

This invention of Shimizu as issued in the patent is in some degreerestricted to GaN semiconductors and claims garnet fluorescentmaterials. [See for example, Schlotter, P. et al., “Luminescenceconversion of blue light emitting diodes”, Applied Physics A, SpringerVerlag (publ.), April 1997, vol. 4, pp. 417-418.]

A later issued invention of similar heritage discloses a light emittingdevice comprising a component capable of emitting blue light, and anopal coating member covering said light emitting component andcontaining a yellow phosphor capable of absorbing a part of blue lightemitted by said light emitting component and emitting light ofwavelength different from that of the absorbed light. (Shimizu, et. al.,U.S. Pat. No. 6,069,440 (filed on Apr. 28, 1999; claims priority date ofJul. 29, 1996[JP] 8-198585; Sep. 17, 1996[JP] 8-244339; Sep. 18,1996[JP] 8-245381; Dec. 27, 1996[JP] 8-359004; Mar. 31, 1997[JP]9-081010) issued on 30 Mar. 2000) The opal coating bears no protectingand enhancing function.

Notwithstanding the above, the same claims using a fluorescent materialwith two blue light emitting diode (that is, two diode of the samewavelength) where the fluorescent material primarily acts as ascattering layer so as to obscure two point sources. (Shimizu et. al.,issued Japanese Patent JP10097200 with a publication date of 1998 Apr.14, application number: JP19970147337 filed on 20 May 1997)

Finally, as discussed in chapter 10.4 of “The Blue Laser Diode” by S.Nakamura et al., pages 216-221 (Springer 1997), incorporated herein byreference, white light LEDs can be fabricated by forming a ceramicphosphor layer on the output surface of a blue emitting semiconductorLED. The blue LED is an InGaN single quantum well LED, and the phosphoris a cerium doped yttrium aluminum garnet Y3Al5O12:Ce3+(“YAG:Ce”). Theblue light emitted by the LED excites the phosphor, causing it to emityellow light. The blue light emitted by the LED is transmitted throughthe phosphor and is mixed with the yellow light emitted by the phosphor.The viewer perceives the mixture of blue and yellow light as whitelight. This invention is based on the fact that yellow light is asecondary color, a combination of red and green light and when red andgreen and blue are combined, as taught by Baretz et. al. [2003] whitelight is obtained. [Interestingly, if a yellow complementary color mixedwith blue can provide a white light, one would argue that a blue-green(also called cyan) complementary color mixed with red can provide awhite light. See Mueller-Mach et. al. in JP2002016295, EP1150361, U.S.Pat. No. 6,603,258]

Osram's research and commercial efforts on white light LEDs aredocumented and detailed: the self-asserted operable United Statespatents which have advanced the art for solid-state white light includeU.S. Pat. No. 6,613,247 “Wavelength-converting casting composition andwhite light-emitting semiconductor component”, U.S. Pat. No. 6,592,780“Wavelength-converting casting composition and white light-emittingsemiconductor component”, U.S. Pat. No. 6,576,930 “Light-radiatingsemiconductor component with a luminescence conversion element”, U.S.Pat. No. 6,066,861 “Wavelength-converting casting composition and itsuse”, U.S. Pat. No. 6,245,259 child to U.S. Pat. Nos. 6,066,861,6,277,301, a continuation of U.S. Pat. Nos. 6,066,861, 6,592,780 acontinuation of U.S. Pat. Nos. 6,245,259, and 6,613,247“Wavelength-Converting Casting Composition and White Light-EmittingSemiconductor Component”. (Documents associated with Complaint of OsramGmbH and Osram Opto Semiconductors GmbH under Section 337 of the TariffAct of 1930, as Amended; In the Matter of Certain Light-Emitting Diodesand Products Containing the Same; United States International TradeCommission; Investigation Number 337-TA-512, Washington, D.C. 20436) TheU.S. Pat. No. 6,576,930 does not define the term “white light” but doesspecify “The hue (color locus in the CIE chromaticity diagram) of thewhite light . . . ” Since achromatic light has no hue, the patent doesnot teach to achromatic light. The same patent at times refers to whitelight as polychromatic light and as white light of mixed color.

U.S. Pat. No. 6,066,861 speaks to a composition containing pigments thatconvert light of one wavelength (e.g., blue, green, or ultravioletlight) to light of another wavelength (e.g., yellow light). They alsorelates to light-emitting semiconductor components containing thiscomposition. The principal application—the conversion of blue light toyellow light in white LEDs—is not claimed. The invention is specific toan “epoxy casting resin”, the term “casting” is not defined. The childrefers to phosphors containing cerium ion. The continuation refers to acomposition that contains epoxy casting resin and pigments havingphosphors selected from the group consisting of Ce-doped phosphors;garnets doped with rare earths; thiogallates doped with rare earths;aluminates doped with rare earths; and orthosilicates doped with rareearths. It is generally understood, in the context of luminophors, thatpigments are inorganic luminescent materials that have color prior tophoto-activation and that dyes are organic luminescent materials thathave color prior to photo-activation. When using epoxy casting resin,many approaches have been used to deposit phosphor onto the LED, suchas, for example, a time-pressure technique and a roller coatingtechnique. Each of these approaches and many others are designed to fillup a reflector cup of the LED with phosphor. However, the volumetricaccuracy is typically unsatisfactory due in part to the settling of thephosphor within the solution. Another disadvantage is a result of theprocess of mixing phosphor compounds with an optically-clear substance,such as, for example a clear epoxy resin. It is difficult to achieve andduplicate a uniform mixture of the phosphor compound particles in theoptically-clear substance. This difficulty results in a less thandesirable uniformity of the light emission from the lighting device.

The blue LED—YAG:Ce phosphor white light illumination system suffersfrom the following additional disadvantages. The blue LED—YAG:Cephosphor system produces white light with a high color temperatureranging from 6000 K to 8000 K, which is comparable to sunlight, and atypical color rendering index (CRI) of about 70 to 75. While the blueLED—YAG:Ce phosphor illumination system with a relatively high colortemperature and a relatively low CRI is acceptable to customers in thefar east lighting markets, the customers in the North American marketsgenerally prefer an illumination system with a lower color temperature,while the customers European markets generally prefer an illuminationsystem with a high CRI. For example, North American customers generallyprefer systems with color temperatures between 3000 K and 4100 K, whileEuropean customers generally prefer systems with a CRI above 90. That isto say, it is desirable from the perspective of general illumination forsolid-state lights to have chromatic light with a hue; likewise, formany other applications—for example as a light source for scanning or asa backlight for displays—it is desirable to produce white light—that isachromatic light without a hue.

Regardless of the adjustment of additional phosphors including redemission phosphors to adjust the color temperature of blue lightemitting diodes with yellow phosphor, this system has one fundamentaland significant problem: the number of blue photons emanating there fromis far greater than the relative number of blue photons in the photopiccurve. In other words, the photons being generated are not useful interms of luminous intensity; this means that the light is not productivefor general illumination. The luminous intensity could increasedramatically if the blue photons were substantively adjusted to greenphotons (near the photopic maximum); heretofore, it has not beensuccessful to dramatically reduce the blue component and to generate aspectral light mimicking the photopic curve using a blue LED die and acomplementary yellow phosphor. This is a fundamental problem that willalways impact the magnitude of brilliance of white LEDs based on bluedie and yellow complementary phosphors. Solid-state lighting based oncombinations of red, green and blue phosphors do not, in theory, havethis fundamental challenge, presuming of course that non-radiativeenergy transfer between the phosphors does not force the spectralemission bathochromic to the photopic curve. Interest in creating anachromatic light using a UV-emitting LED to pump a trio of RGB-emittingof phosphors, UV light is adsorbed by the phosphors, and the mixed RGBoutput appears achromatic much the same as a mixed LED array of red,green and blue LED-dice. In contrast let us note, “The quantum deficitbetween the UV pump and the phosphors, especially the low-energy redphosphor, dissipates significant energy and makes this approachinherently less efficient than either the red, green and blue LED-diceor the phosphor conversion using a blue LED and yellow phosphor emitterschemes for generating white light.” (D.A. Stiegerwald, et. al.,“Illumination With Solid State Lighting Technology”, IEEE JOURNAL ONSELECTED TOPICS IN QUANTUM ELECTRONICS, VOL. 8, NO. 2, March/April 2002)Notwithstanding this observation which relates to conversion ofelectrical energy to photonic energy, we add that the conservation ofenergy does not preclude one quantum of primary radiation to generateonly one quantum of secondary radiation.

Other difficulties attesting to the general undesirability of using blueLED—YAG:Ce phosphor illumination—in the conventional construction atleast—is articulated by Doxsee, Daniel Darcy; et al. within UnitedStates Patent Application 20040135154 (Jul. 15, 2004). Therein theystate “In addition to this somewhat limited emission intensity, thecolor output of such an LED-phosphor system varies greatly due tofrequent, unavoidable routine deviations from desired parameters (i.e.manufacturing systemic errors) during the production of the light. Forexample, the color output of the finished device is very sensitive tothe thickness of the phosphor layer covering the LED. If the phosphor istoo thin, then more than a desired amount of the blue light emitted bythe LED will penetrate through the phosphor and the combinedphosphor-LED output will appear bluish. In contrast, if the phosphorlayer is too thick, then less than a desired amount of the blue LEDlight will penetrate through the phosphor layer. In this case, thecombined phosphor-LED output will appear yellowish. Therefore, thethickness of the phosphor layer is an important variable affecting thecolor output of a blue LED based system. Unfortunately, the thickness ofthe phosphor layer is difficult to control during large scale productionof LED-phosphor lamp systems, and the variations in phosphor thicknessoften result in relatively poor lamp to lamp color control. In addition,lamp to lamp variations occur due to the varying of the optical powerfrom chip to chip.” The solution proposed by Doxsee et. al. (2004) isreplacement of blue LED die with uv LED die (“emitting in the 380-420”nm range according to the definition of Doxsee et. al. of a uv emittingdiode die) and the utilization of uv excited phosphor blends to generatewhite light: BaMg2Al16O27:Eu2+ with a second phosphor where the secondphosphor is a terbium aluminum garnet. Note that the first phosphor useseuropium instead of the cerium in YAG:Ce and that the yttrium aluminumgarnet—an yttrium aluminum oxide in a garnet crystal structure—isreplaced with a barium magnesium aluminum oxide. The second phosphorclaimed by Doxsee et. al. (2004) is Tb3Al4.9O12:Ce where the ceriumcomplexes not with YAG (an yttrium aluminum oxide in a garnet crystalstructure) but with terbium aluminum oxide in a garnet structure. Doxseeet. al. sequester the phosphors claimed either as a layer on the LED dieitself [The phosphor, radiationally coupled to the LED chip, isdeposited on the LED by any appropriate method . . . (for example, awater based suspension of the phosphor(s) can be formed, and applied asa phosphor layer to the LED surface by coating and drying the phosphorsuspension over the LED chip)] or where the phosphor powder may beinterspersed within a single region of the encapsulant material or, morepreferably, throughout the entire volume of the encapsulant material.

Doxsee et. al. teach the preparation of terbium aluminum garnetcomplexed with cerium, for example, with the following specifications:The TAG phosphor for use in the phosphor blend of the present inventionmay be produced by a method comprising the steps of: (1) providingstoichiometric amounts of oxygen-containing compounds of terbium;oxygen-containing compounds of at least one rare-earth metal for exampleCe; and oxygen-containing compounds of at least one member selected fromthe group consisting of for example Al; (2) mixing together theoxygen-containing compounds to form a mixture; and (3) firing themixture in a reducing atmosphere at a temperature and for a timesufficient to convert the mixture to a rare earth-activatedterbium-containing garnet phosphor. Doxsee et. al. teach that thereducing atmosphere may optionally be diluted with an inert gas, such asnitrogen, helium, neon, argon, krypton, xenon; subsequent to thepreparation of the TAG phosphor, these inert gases are not utilized byDoxsee et. al.

The challenge in utilizing ceramic phosphors for the generation ofachromatic white light (light without hue) is formidable at best andmost difficult and expensive at worst and has led to extremelycomplicated mixtures of ceramic phosphors to effect achromatic whitelight. For example, in U.S. Pat. No. 6,084,250, Justel, et. al. claim awhite light emitting diode comprising a UV-diode with a primary emissionof 300 nm through 370 nm and a phosphor layer including a combination ofa blue-emitting phosphor having an emission band, with 430 nm through490 nm, a green-emitting phosphor having an emission band, with 520 nmthrough 570 nm and a red-emitting phosphor having an emission band, with590 nm through 630 nm, emits high-quality white light. Thecolor-rendering index CRI is approximately 90 at a color temperature of4000 K. The color rendition depends only on the composition of the threephosphors, not on the relation between converted and non-convertedlight, and hence can be readily controlled and regulated.

Even when a broadly used single ceramic phosphor is available, ultimateperformance is compromised. Shimizu et al. describes various phosphorLEDs that generate white output light having a color temperaturesomewhere between 5,000 to 6,000 degrees Kelvin. (Shimizu, et. al.; PCTApplication number WO1997JP02610 Jul. 29, 1997, published as WO98/05078: “Light Emitting Device and Display Device”) In one embodiment,the LED of Shimizu et al. utilizes a yttrium aluminum garnet (YAG)phosphor to convert some of the primary light into secondary lighthaving a peak wavelength of about 580 nm. The spectral distribution inthis embodiment has two emissions peaks; one peak is predominatelycaused by the primary light emitted from the GaN die of the Shimizu etal. and the other peak is predominately caused by the secondary lightemitted from a yttrium aluminum garnet phosphor.

A concern with the Shimizu et al. LED is that the “white” output lighthas an undesirable color balance for a true color rendition. The outputlight of the Shimizu et al. LED is adequate for applications in whichsimple illumination is required. However, for applications in which ahigh color rendition is desired, the output light is deficient in thered region of the visible light spectrum (647-700 nm range).

As an example of another disclosure where an improved phosphor isclaimed, see for example, in the issued U.S. Pat. No. 6,680,569, whereMueller-Mach, et al. discloses a light emitting device which includes alight source that emits first light in response to an electrical signal,and a fluorescent layer positioned over the light source. Thefluorescent layer includes a first fluorescent material which radiatessecond light and a second fluorescent material—which must “comprise” anitrido-silicate—which radiates third light. The invention ofMueller-Mach, et. al. discloses the use of a yttrium aluminum garnet(YAG) phosphor in general or a cerium-activated yttrium aluminum garnet,more specifically, as the first fluorescent material and comprises anitride-silicate which radiates red light. Hence, whereas the disclosureof Shimizu et. al. uses a single phosphor to emit polychromatic lightand the primary radiation of the semiconductor light emitting diode die,the disclosure of Mueller-Mach, et. al. uses two fluorescent materialsto emit polychromatic light with a greater red contribution than thatotherwise available from a yttrium aluminum garnet phosphor as a singlephosphor, by itself. The mechanism by which the nitride-silicate whichradiates red light is brought to its excited state is not articulated.Further, there is a requirement that the primary radiation “emits firstlight” and that this occurs as a response to an electrical signal. Thiswording would seem to preclude non-radiative energy transfer between thep-n junction and the first fluorescent material.

Other ceramic phosphors are continuously being discovered and theirbenefits taught. (Y. Tian et. al.; United States Patent Application20040173807; publication date Sep. 9, 2004; hereinafter Tian et. al.[2004]) For example, recently RCA Lab's spin-off SarnoffLaboratories—home of initial work on GaN semiconductors with theirtreasure trove of phosphors initially developed for colortelevision—claim the garnet phosphor having the following composition:Y3(Al1-sGas)5O12:Ce:XBaAl2O4 wherein s is equal to or greater than 0 andless than or equal to 1; x is from 0.01 to 0.3. The phosphor pioneerYocum and colleagues at Sarnoff found that by substituting bariumfluoride, or other alkali metal or alkaline earth metal halide, as aflux during manufacture of a trivalent cerium activated, yellow emittingyttrium aluminum garnet phosphor and heating the mixture at from1400-1500.degree. C., enhanced fluorescence emission is obtained, whilemaintaining the wavelength emission properties. The resultant phosphorhas a small alkali metal or alkaline earth metal alumina halidecrystalline second phase in the phosphor, generally about 1% whichenhances its emission intensity in the yellow range: called a “two-phasephosphor”. Notwithstanding this important and impressive accomplishment,small increases in the quantum yield of yttrium aluminum garnetphosphors while important and beneficial in commercial implementationsare not thought to be critical parameters in the long term goal ofreplacing incandescent lighting with solid-state lighting.

Nevertheless, at least a systematic approach towards designs of newceramic phosphors is emerging. (Tian et. al. [2004]) As described, theyellow-emitting cerium doped yttrium aluminum garnet (YAG) phosphorshave been known for some time. It is also known that the emissionwavelength of these phosphors can be shifted to longer wavelengths whengadolinium is partially substituted for yttrium. Along with therealization that larger ions partially substituted for aluminum shiftedthe emission wavelength to shorter wavelengths for these phosphors, anapproach towards garnet phosphor design is apparent. Cerium-dopedyttrium aluminum garnet phosphors generally emit in the 500-750 nmrange, with a peak at 550 nm. The exact peak obtained depends on theconcentration of Cerium. (Tian et. al. [2004])

Other ceramic phosphors reported (Yocom, Perry Niel; et al.; UnitedStates Patent Application 20030222268, Dec. 4, 2003) to have utilityinclude:

1. phosphors that emit in the range of from about 550 to about 750 nminclude calcium magnesium silicate activated with europium and/ormanganese (CaMgSi2O6:Eu+2, Mn+2) and strontium lithium silicateactivated with tin and/or manganese (Sr2Li2Si2O7:Sn+2, Mn+2);

2. a phosphor that emits in the range of about 650 to about 750 nm isaluminum oxide (alumina) activated with titanium (Al₂O₃:Ti+3);

3. a phosphor that emits in the range of about 750 to about 1100 nm iscadmium sulfide activated with copper and/or chlorine (CdS:Cu+2,Cl);

4. a phosphor that emits in the range from about 1100 to about 1300 nmis magnesium silicate activated with chromium (Mg2SiO4:Cr+4);

5. a phosphor that emits in the range from about 1200 to about 1400 nmis yttrium silicate activated with chromium (Y2SiO5:Cr+4)

In addition, red-emitting strontium-calcium sulfide phosphor doped witheuropium and a halide has been reported. (Tian, Yongchi; et al., UnitedStates Patent Application 20030132422; publication date Jul. 17, 2003) Atwo phosphor component white light (based on two complementary colors)containing is reported: the first phosphor is an orange emitting Eu2+,Mn2+ doped strontium pyrophosphate, (Sr0.8Eu0.1Mn0.1)2P2O7; the secondphosphor is a blue-green emitting Eu2+ doped SAE, (Sr0.90-0.99Eu0.01-0.1)4Al14O25. (Srivastava, et. al.; Canadian Patent ApplicationCA 2375069)

As one skilled in the art would appreciate, the discovery of newinorganic materials for specific luminescent applications—especiallythose amenable to their use in the manufacture of consistent and highquality light emitting diode lamps—is a challenge. The preparation anddiscovery of new solid state inorganic compounds is limited by the lackof a general framework that provides broad based predictive syntheticstrategies and theories. Due to the lack of predictive tools availableto the solid state inorganic chemist, the preparation of new phosphorshas generally been restricted to serial synthesis and analysistechniques. As such, serial synthesis and testing of powder phosphorshas been the discovery and development paradigm for the last one hundredand fifty years. “Such techniques have resulted in the discovery of lessthan one hundred phosphors suitable for commercial use” (see, Vecht, SIDSeminar Lecture Notes, 2, F-2/3 (1996); Ropp, The Chemistry ofArtificial Lighting Devices, Elsevier, Amsterdam, pp. 414-656 (1993)).At the same time, efforts to predict basic solid state properties fromtheory, including intrinsic or extrinsic luminescent efficiency, havebeen unsuccessful (see, DiSalvo, Science, 247:649 (1990)). Usingtraditional methods, fewer than 1% of all possible ternary compounds andless than 0.01% of all possible quaternary compounds have beensynthesized heretofore (see, Rodgers, et al., Mat. Res. Bull., 18:27(1993)). Combinatorial techniques have been helpful (see U.S. Pat. No.6,315,923 “Storage phosphors”; U.S. Pat. No. 6,203,726 “PhosphorMaterials” and U.S. Pat. No. 6,013,199 “Phosphor materials”) but thechallenge and cost associated with complex combinatorial ceramics isformidable.

In contrast, organic compositions of matter are readily produced andconceived and the art of conjugation in molecular design is appreciatedand easily practiced. Organic luminophors in general and organicfluorescent and organic phosphorescent materials have extremely broademission profiles, are relatively inexpensive to manufacture and a wellaccepted paradigm exists for the organic chemist skilled in the art tomolecularly design emission profiles of useful characteristics. Theyalso have high quantum yields of luminescence: the quantum efficiency ofthe organic Lumogen dyes in solution is >0.98 and no loss in efficiencywas observed with a polymethylmetacrylate (PMMA) host whereas thequantum yield of the ceramic phosphor Y(Gd)AG:Ce doped was measuredrelative to a known standard and found to be 0.86. (A.R. Duggal, J.J.Shiang, C.M. Heller, and D.F. Foust, “Illumination Quality OLEDs forLighting” Technical Information Series GE Global Research TechnicalReport 2002GRC189, August 2002) Notwithstanding the appeal of organicluminophors, there have been only a few examples, other than that taughtby Baretz et. al. [2003] of organic fluorescers being used inDown-Conversion in solid-state lighting with a p-n junction.

In a series of experiments imitating down-conversion, it has beenreported that thin films of dilute organic dyes in amorphous inorganicmatrix materials may be promising materials for optoelectronic devicesbased on luminescence conversion, because the separation andimmobilization of the dye molecules by the matrix reduces non-radiativerelaxation processes of excited molecules in bulk dyes. High quantumefficiencies were demonstrated in such diluted systems realized bysol-gel technique or by incorporation in organic matrices. However, theroom temperature photo-stability in these systems is not suitable formany applications based on the luminescence. As an improvement, it wassubsequently found that an organic-inorganic system prepared byco-evaporation of the components in high vacuum which allows (i) to usevery stable dye molecules independent of their solubility in the matrix,(ii) to use different substrates and (iii) which results in homogeneousdye molecule distribution. In dependence on dye concentration,absorption and luminescence spectra change dramatically due to thechanges in intermolecular distance and surrounding. For the lowerconcentrations, both absorption and luminescence spectra can bedescribed as monomer transitions with vibrational progression andbroadened peak widths. In the system perylene-3, 4, 9,10-tetracarboxylic-dianhydride in silicon dioxide (silica) the maximumphotoluminescence quantum efficiency is obtained at a concentration ofabout 0.1 volume % as expected from energy transfer processes betweenthe molecules, which were analyzed by luminescence anisotropymeasurements. (H. Froeb, M. Kurpiers, K. Leo “Highly Efficient andPhotostable Organic Dyes in Inorganic Matrices: A Novel Path toLuminescence Conversion Devices.”, Institut fur Angewandte Photophysik,Technische Universitaet Dresden, Dresden, GERMANY. Proceedings publishedas Volume 560 of the Materials Research Society Symposium ProceedingsSeries, Apr. 7, 1999.) The important observation is that even when theorganic luminophor has extremely high quantum yields of luminescence(e.g.; 98% for Lumogen organic luminophors, nearly quantitative for thebis(phenylethynyl)anthracenes), under high photon flux alternativemechanisms of deactivation ultimately lead to a measurable altering ofthe initial structures. In many cases, the “leakage” results frombimolecular events—aggregation; excimer formation is energeticallyfavorable but leads to alternative reactions, non-radiative decay andgenerally lower yields of radiative decay (luminescence). Agglomerationalso occurs in ceramic phosphors and is also thought to be a reason forlong term luminophor instability; that ceramic particles are not solublein epoxy matrices enhances agglomeration. In any case, sequestering anorganic luminophor in a silica matrix is similar to sequestering theluminescent Ce ion within a garnet structure. Note that the vacuum wasused to disperse the dyes and that once dispersed the vacuum wasreleased, all prior to radiation.

Hide, et. al. reported a hybrid Light-Emitting Diode for white lightingand for full-color applications [Hide, F.; DenBaars, S. P.; and Heeger,A.J.; U.S. Pat. No. 5,966,393, filed on 4 Feb. 1997, priority date of 13Dec. 1996 from provisional application No. 60/032,849; issued 12 Oct.1999]. Hide, et. al., claim a photoluminescent polymer—aphotoluminescent conjugated semiconducting polymer—which down-convertslight from a solid-state inorganic light-emitter.

A similar disclosure was reported by Zhang, C.; et. al. entitled“Gallium nitride/conjugated polymer hybrid light emitting diodes:Performance and lifetime.” [Chi Zhang and Alan J. Heeger, Journal ofApplied Physics—Aug. 1, 1998; Volume 84, Issue 3, pp. 1579-1582;Received 12 Jan. 1998; accepted 28 Apr. 1998] In this disclosure a “purewhite” light emission from GaN/conjugated polymer hybrid light emittingdiodes (LEDs) using a single layer of conjugated polymer was reported.When the conjugated polymer is properly encapsulated, the report statesthat the hybrid LEDs can operate at least 5000 h, with decay in outputluminosity comparable to that of commercial blue GaN lamps. By usingdifferent conjugated polymers, emission with a full range of colors isdemonstrated with the hybrid LED. [Also “White light fromInGaN/conjugated polymer hybrid light-emitting diodes”, F Hide, PKozodoy, SP Denbaars, AJ Heeger; Applied Physics Letters 70(20), 2664(1997)]

Bojarczuk et. al., disclosed a hybrid organic-inorganicsemiconductor-based light-emitting diode [Bojarczuk, Jr.; Nestor A.;Guha; Supratik; Haight; Richard Alan; filed Mar. 5, 1997; issued Apr.20, 1999, U.S. Pat. No. 5,895,932; priority date of Jan. 24, 1997 fromSer. No. 08/788,509]. This invention provides a novel hybridorganic-inorganic semiconductor light emitting diode. The deviceconsists of an electroluminescent layer and a photoluminescent layer.The electroluminescent layer is an inorganic GaN light emitting diodestructure that is electroluminescent in the blue or ultraviolet (uv)region of the electromagnetic spectrum when the device is operated. Thephotoluminescent layer is a photoluminescent organic thin film such astris-(8-hydroxyquinoline) Al, Alq3, deposited onto the GaN LED and whichhas high photoluminescence efficiency. The uv emission from theelectroluminescent region excites the Alq3 which yields luminance in thegreen. Such a photoconversion results in a light emitting diode thatoperates in the green (in the visible range). Other colors such as blueor red may be obtained by appropriately doping the Alq3. Furthermore,other luminescent organics in addition to Alq3 may be used to directlyconvert the uv or blue to other wavelengths of interest. The inventionprovides the benefits of simplicity and ease of fabrication, since acomplete redesign of the structure is not necessary to change emissionwavelength, and the possibility for making displays by spatially varyingthe deposition of the emissive layer. This invention claims a hybridorganic-inorganic semiconductor light emitting diode comprising, insequence, a substrate, a n-doped semiconductor layer, a light emissionregion where electrons and holes recombine to produce light, a p-dopedsemiconductor layer, and a layer of an organic photoluminescent materialwhich comprises a fluorescent compound or combination of compounds whichabsorb light at the wavelength emitted by said light emission region andre-emit light at a different wavelength. This invention is limited to “alayer of an organic photoluminescent material.”

In U.S. Pat. No. 5,898,185, Bojarczuk, Jr., et al. (1999a) claim ahybrid organic-inorganic semiconductor light emitting diode consistingof a layer of a light emitting, inorganic electroluminescent materialand an overlying layer of an organic photoluminescent material or ahybrid organic-inorganic semiconductor light emitting diode consistingof, in sequence, a substrate, an n-doped semiconductor layer, a lightemission region where electrons and holes recombine to produce light,and a p-doped semiconductor layer and further including a layer of anorganic photoluminescent material. [Bojarczuk, Jr.; Nestor A.; Guha;Supratik; Haight; Richard Alan; issued Apr. 27, 1999; filed 5 Mar. 1997;a continuation-in-part of application Ser. No. 08/788,509, filed Jan.24, 1997.] This invention is limited to a “layer of an organicphotoluminescent material.”

Guha et. al. disclosed a hybrid organic-inorganic semiconductor-basedlight-emitting diode [received 7 Mar. 1997, accepted 11 Jul. 1997,published 15 Oct. 1997; Journal of Applied Physics, Volume 82, Issue 8,pp 4126-4128] whereby a GaN-based light emitting diode emits shorterwavelength light and an organic thin-film part that absorbs theelectro-luminescence (the primary radiation) and fluoresces at a longerwavelength resulting in color conversion. (See also “Efficient white andred light emission from GaN/tris-(8-hydroxyquinolato)aluminum/platinum(II) meso-tetrakis(pentafluorophenyl) porphyrin hybridlight-emitting diodes”, Hai-Feng Xiang, Sze-Chit Yu, Chi-Ming Che, andP. T. Lai, Applied Physics Letters Vol 83(8) pp. 1518-1520. Aug. 25,2003.)

Not withstanding the progress made in using organic fluorescers orceramic phosphors as down-conversion luminescent elements, the currentstate of the art finds it difficult to generate achromatic light orchromatic light using down-conversion with reasonable operationallifetimes.

Though organic fluorescers with extremely high quantum yields offluorescence, which by definition necessitate short excited statelifetimes and are unlikely to be quenched or degraded by oxygen or otherreactants, nevertheless degrade over an extended period of operationwhich solid-state LEDs find themselves. Hence, ceramic phosphormaterials have been the luminescent element of choice from theperspective of operational durability.

What ceramic phosphors gain—in theory—from the perspective of stability,they lose from the standpoint of performance. Ceramic phosphors ingeneral have two major limitations: they are not soluble in the matrixthat envelopes the light emitting diode die and the ability of ceramicphosphors to mimic the photopic light curve has been fraught withchallenges. In the case of the former, an extensive non-intuitivediscussion is stated within United States Patent Application 20030227249(Mueller, Gerd O.; et al., publication date Dec. 11, 2003). Organicfluorescers generally do not have these difficulties in solubility norin finding a broad set of luminophors, either fluorescent and orphosphorescent, to match the spectral distribution of the photopic lightcurve.

It has been demonstrated by Butterworth, et. al. (WO9902026 in a patentapplication with the title Fluorescent Dye Added to Epoxy of LightEmitting Diode Lens) that a standard blue GaN light emitting diode withblue light emission at 470 nm efficiently radiatively transfers itsenergy to Coumarin 6 (for green emission), Fluorol 7 (for yellow greenemission) and to Rhodamine 110 (for yellow emission). In contrast,Butterwoth notes that ceramic phosphors are not soluble in the epoxylens used to focus light emitting diode die and substantial scatteringoccurs. (See also Doxsee et. al., U.S. Pat. No. 6,791,259, issue dateSep. 14, 2004 where organic luminescent dyes are utilized and titaniumdioxide is used as a scattering agent to form a Lambertian surface, eventhough titanium dioxide is, itself, photo-active and often leads tomolecular degradation through electron transfer reactions.)

Scattering by phosphor particles of primary emission from asemiconductor device and of secondary emission from the phosphorparticles themselves may be reduced by reducing the size of the phosphorparticles to substantially below wavelengths (e.g., peak wavelengths) ofthe primary and secondary emission. For example, semiconductornano-crystals or semiconductor quantum dots, which typically have adiameter less than about 10 nm and hence scatter little of the primaryand secondary light, may be used as substantially non-scatteringphosphors. The use of semiconductor nano-crystals and quantum dots tophosphor convert the output of a light-emitting semiconductor device isdisclosed in U.S. patent application Ser. No. 09/167,795 and in U.S.patent application Ser. No. 09/350,956, both of which are incorporatedherein by reference in their entirety. These references do notrecognize, however, the significant losses due to scattering by largephosphor particles in conventional phosphor converted light-emittingdevices and the consequent advantages to be realized by usingnon-scattering phosphor particles instead. Further, quantum dots areconstructed from elements that may be viewed as the solid-statetoxicological equivalent of Hg in fluorescent lamps.

Environmental Effects for Instantaneous and Long Term Performance

Prior to this invention, the advantages of effecting solid-statelighting from light emitting diodes in a vacuum was not appreciated andin fact, the art taught away from vacuum LEDs. (1. Stanton, et. al.[1997] in WO9748138; 2. Moyer, et al., U.S. Pat. No. 5,334,855; issuedAug. 2, 1994). Further, the advantages of placing the luminescentelement in a media other than the epoxy polymer or a similar siliconpolymer enveloping a light emitting diode has generally not beenappreciated. (1. Yosaki, Japanese Patent number: JP5152609; Publicationdate: 1993-06-18; Application number: JP19910336011 19911125. 2.Butterworth, et al., Issued United States Patent U.S. Pat. No.5,847,507, 1998. 3. W. Rossner; United States Patent Application2003025449, publication date Feb. 6, 2003.) It is also the case thatwhile prior art points to external placement of a luminescent element ina separate isolating container as described by Rossner and by Ibbettsonand Tarsa (Ibbetson, et. al., Patent Application WO2004077580;publication date Sep. 10, 2004) the internal placement of a luminescentelement in an isolating chamber, separated from the encapsulating matrixand allowing for the creation of a controllable environment therein hasnot been, prior to this invention, been recognized. (I. Umio, JapanesePatent number: JP62189770; Publication date: Aug. 19, 1987) When thelight emitting diode die and its active layer are similarly placed in acontrollable environment, such as is only heretofore practicable by thisinvention, the performance of the underlying semiconductor is alsoenhanced. [As reported athttp://www.chem.wisc.edu/˜ellis/Research/res1.html—I. Chemical SensorsBased on Semiconductor Luminescence {Supported by NSF Grants BES-9980758and CTS-9810176} “ . . . band edge photoluminescence (PL) of II-VIsemiconductors like CdSe can be modulated by adsorption of moleculesfrom gas and liquid phases. Typically, Lewis bases enhancephotoluminescent intensity and Lewis acids quench it . . . ”). Lastvisited on 9 May 2004.] Ammonia gas is a Lewis base. Lewis bases areelectron donors. The interaction of a Lewis with an operating p-njunction is not clear.

Prior to this invention the ability to limit uv radiation in downconversion and where said uv radiation degrades epoxy resin used to potlight emitting diode die has had limited utility. (1. Reeh, et. al.;U.S. Pat. No. 6,576,930; issued on 10 Jun. 2003. 2. W. Rossner; UnitedStates Patent Application 2003025449, publication date Feb. 6, 2003.) Byusing a chamber that is opaque to uv radiation, only secondary radiationleaves the chamber. Glass that does not transmit uv radiation are wellknown in as photographic UV-1 filters as well as Schott 8688(tungsten-based) and 8271 (kovar) filters.

Despite the robust characteristics of inorganic materials versus theirorganic counterparts, even ceramic phosphors are known to degrade due tomoisture and other factors due to environmental exposure, although theseproblems are more likely recognized by applications of ceramic phosphorsexposed to the environment. Examples are phosphorescent phosphors,sulfide phosphorescent phosphors, which are very well known and sincethey have extremely long radiative lifetimes, are prone to quenching.When the quencher photo-reacts, degradation takes place. Examples ofsulfide phosphorescent phosphors include CaS:Bi (which emits light ofviolet blue), CaStS:Bi (which emits light of blue), ZnS:Cu (which emitslight of green) and ZnCdS:Cu (which emits light of yellow or orange).However, any of these sulfide phosphorescent phosphors are chemicallyunstable and shows degraded light resistance, i.e., it suffers fromproblems that must be solved for practical use.

The most extensively used phosphorescent phosphor among such sulfidephosphorescent phosphors is zinc sulfide phosphorescent phosphor (ZnS:Cu). However, zinc sulfide phosphorescent phosphor is decomposed as theresult of irradiation by ultraviolet radiation in the presence ofmoisture and thus blackens or reduces the luminance thereof. Therefore,it is difficult to use this phosphorescent phosphor in fields where itis placed outdoors and exposed to a direct sunlight, that is,application thereof is limited to luminous clocks/watches orclocks/watches and instrument dials, evacuation guiding signs or indoornight-time display. [Murayama, et al., U.S. Pat. No. 5,424,006, issuedate Jun. 13, 1995] Hermetic sealing of these phosphorescentphosphors—prevention of exposure to moisture—is one means of improvinglong term operational stability.

Alternatively, new compositions have been developed as replacements forthese traditional phosphorescent phosphors. For example, SrAl2O4:Eu, astrontium aluminate doped with the rare earth europium, and an aluminumoxide in the spinel structure, has excellent stability against moisture,in comparison with afterglow phosphorescence phosphors of the ZnS class.The general formula of the Spinel Group is AB2O4. The A represents adivalent metal ion such as Magnesium, Iron, Nickel, Manganese and/orZinc. The B represents trivalent metal ions such as Aluminum, Iron,Chromium and/or Manganese. The gemstone spinel also has the spinelstructure and is similar in elemental composition to ruby. Spinel andruby are chemically similar. Spinel is magnesium aluminum oxide (that isto say, magnesium aluminate) and ruby is aluminum oxide. The redcoloring agent in both spinel and ruby is the same element, sometimesreferred to as a dopant, chromium.

However, these new spinel phosphors are prepared with expensiveingredients [for example, one adds europium oxide to strontium carbonateand alumina and boric acid is added as flux thereto] and expensiveprocessing conditions [after the resultant mixture was sufficientlymixed using a ball mill, the sample was fired for 1 hour at 1300° C. ina stream of nitrogen-hydrogen mixture gas (97:3) (flow rate: 0.1liter/min) using an electric furnace.]

Phosphorescent phosphors of a general type may be used in anillumination device utilizing a pulse modulation technique to provideincreased light output for a given heat load. For example, the issuedpatent notes that when power is supplied in pulses to periodicallyactivate a short wavelength (i.e., blue) emitting LED, which in turnstimulates a phosphor-based color conversion system to produce sustainedwhite light. In response to a pulse of power, the LED emits an intenseburst of short wavelength light. The burst of light from the LED brieflyexcites the phosphor system, producing a bright illumination. During theinterval while power is dissipated in the LED, the LED warms. After thepulse ends and before the next pulse begins, the LED cools because nomore power is dissipated in the LED. However, the phosphorescentbehavior of the phosphor system causes it to continue to glow for aperiod of time after being excited. The intensity of the illuminationproduced by the phosphor gradually decays during this period. Theaverage illumination produced by the preferred embodiment over theentire period from the beginning of one pulse to the beginning of thenext is higher than a conventional LED illumination device usingconstant power dissipation for a given heat load. (Schmidt; Gregory W.;U.S. Pat. No. 6,028,694; issue date Feb. 22, 2000) This method isproposed as a means of managing the heat load of a solid-state lightingdevice. While ingenuous in conception, the method may not be practicablein implementation as described to generate a level emission of light.

Whereas the europium doped strontium aluminate is used as aphosphorescent phosphor, a europium doped strontium silicate for whitelight LED down-conversion has been recently described. (Joung Kyu Park,Kyoung Jae Choi, Chang Hae Kim, Hee Dong Park, and Se Young Choi,“Optical Properties of Eu2+-Activated Sr2SiO4 Phosphor forLight-Emitting Diodes”, Electrochemical and Solid-StateLetters—2004—Volume 7, Issue 5, pp. H15-H17)

Vacuum Lighting Products

Recently, there are wide-spread developments of vacuum ultravioletray-excited, light-emitting diodes having a mechanism in which afluorescent substance is excited by vacuum ultraviolet ray radiated byrare or Noble gas discharge to emit light, and development of plasmadisplay panels (PDPs) is a typical example thereof. This discharge iseffected by electrodes. A PDP enables increase in size of an image planewhich is difficult to achieve in cathode-ray tubes (CRT) and colorliquid crystal displays, and are expected to be used for flat paneldisplays in public spaces or as a large screen television. A PDP is adisplay device obtained by placing a large number of fine dischargingspaces (hereinafter, sometimes abbreviated as display cell) into amatrix arrangement. A discharge electrode is provided in each displaycell and a fluorescent substance is applied on the inner wall of eachdisplay cell. Each display cell is filled with a rare or Noble gas suchas He—Xe, Ne—Xe, Ar and the like, and by applying voltage on a dischargeelectrode, discharge occurs in the rare or Noble gas and vacuumultraviolet ray are radiated. The fluorescent substance is excited bythe vacuum ultraviolet ray and emits visible ray. The term vacuumultraviolet ray is known to mean a photon in the vacuum uv which isknown to represent the wavelengths of 100 nm to 200 nm, whereas UVA isknown to represent 315 nm to 400 nm, UVB is known to represent 280 nm to315 nm, UVC is known to represent 200 to 280 nm. By use of fluorescentsubstances emitting three primary colors, blue, green and red, fullcolor display can be achieved.

A vacuum ultraviolet ray-excited light-emitting device other than a PDPis a rare gas lamp. A rare gas lamp emits light by a mechanism in whichvacuum ultraviolet ray are generated by discharge in a rare gas, and thevacuum ultraviolet ray is converted to visible light. These lamps haveelectrodes. The luminescent component of a rare gas lamp may be analuminate phosphor, luminophor and or fluorophor. When the aluminate isa luminous material which has, independent of its incorporation into therare earth gas lamp, high afterglow brilliance then the rare earth gaslamp has high afterglow. Rare gas lamps are expensive; they operateextremely high ultraviolet energy. A rare gas lamp or a PDP has a cellwhich is filled with a rare gas such as He—Xe, Ne—Xe, Ar and the like,and by applying voltage on a discharge electrode, discharge occurs inthe rare gas and vacuum ultraviolet ray are radiated. The fluorescentsubstance is excited by the vacuum ultraviolet ray and emits visibleray. It is clear to one of ordinary skill that a key element of theserare gas lamps are that they operate in the vacuum uv, that they have adischarge element and that the discharge element operates in the vacuumuv. It is also possible for a vacuum uv lamp—that is one that generatesvacuum uv rays as its primary radiation—to generate a secondary photonin the vacuum uv with the use of vacuum uv phosphors, analogous to arare-gas lamp. (Keiji, et. al., Japanese Patent Number JP2004115659;issue date Apr. 15, 2004)

As noted above, phosphors may be used in rare gas lamps. Whereas most ofthe light emission in a mercury vapor lamp is at 254 nm, in contrast,most of the ultraviolet light emitted by xenon occurs at a wavelength of172 nm (the vacuum uv), corresponding to a higher energy than thatassociated with mercury. As a result, new phosphors are needed that canefficiently absorb 172 nm ultraviolet light and convert it to red, greenand blue wavelengths. It is relatively simple to find materials—based onthe lanthanide elements, for example—that efficiently absorb theultraviolet output of xenon. But the true challenge in working withxenon as a discharge medium is finding phosphors that efficientlyconvert the ultraviolet output of xenon into visible light. Two generalconsiderations govern phosphor conversion efficiency: quantum efficiencyand energy mismatch. Quantum efficiency measures the number of visiblephotons produced by the phosphor for every ultraviolet photon absorbed.High quantum efficiency means that once a phosphor is excited to itsemitting state, it returns to its ground state primarily by emittinglight. The efficiency is reduced if, instead, the excited state decaysnon-radiatively by dissipating heat via phonon emission. Highlyefficient phosphors can be designed by varying the luminescent elementor ion and the chemical composition of the host lattice. Energy mismatchrefers to the difference in energy between the photons that are absorbedand emitted by the phosphors. Since red, green and blue photons are muchless energetic than ultraviolet photons, a considerable mismatch ofenergy is associated with most phosphors. In all phosphor materialsknown until now, this energy mismatch has led to non-radiative decays ofthe luminescent element or ion (once the energy had been transferredradiatively from the primary radiation to the luminescent elements).Energy mismatch has therefore been an unavoidable, inefficient use ofthe electrical excitation energy in fluorescent lighting. Theinefficiency due to energy mismatch is much more severe for xenon thanmercury because of the much higher ultraviolet output energy of xenon(7.2 eV compared with 4.9 eV).

However a new phosphor for xenon rare-gas lamps has been discovered: thediscovery of the phosphor material europium-doped lithium gadoliniumfluoride, LiGdF4:Eu3+. This phosphor is capable of producing red lightefficiently when excited with vacuum ultraviolet light output from thexenon. Since the energy of 172 nm xenon photons is more than double theenergy of red, green or blue photons, it should be possible to obtaintwo visible photons for every ultraviolet photon absorbed by thephosphor. In other words, it should be possible to recover an extravisible photon from the energy mismatch instead of losing itnon-radiatively as had always been observed previously. But the emissionof two visible photons by sequential emission from a single luminescentelement or ion had never been observed in phosphors of the type used inlighting. The researchers designed a phosphor in which a luminescentelement of europium ions interacted with the lithium gadolinium fluoridehost lattice. The gadolinium ions in the host lattice apparently absorbsthe energy from the high energy ultraviolet light and then transfer itto europium ions to obtain visible light. If the transfer of energyoccurred simply between one gadolinium ion and one europium ion,(non-radiative energy transfer) the phosphor would suffer from asignificant energy-mismatch problem and would have low efficiency.However, the strategy used in the design of the LiGdF4:Eu3+ phosphoravoids this problem because two different mechanisms for transferringenergy from the gadolinium ions to the europium ions are present. Thefirst stage involves the gadolinium ions absorbing the ultravioletlight, resulting in a highly excited state (step 1). The excitedgadolinium ion next transfers energy to a europium ion (step 2). Thisexcites the europium ion to a higher state, which subsequently emits avisible photon. During the energy transfer, the gadolinium ion decaysfrom its original excited state to a lower-energy excited state. Thisexcited state is still higher in energy than red, green or blue photonsand the gadolinium ion continues to decay through a secondenergy-transfer process (step 3). This energy-transfer process returnsthe gadolinium ion to its ground state and excites a second europium ionto a high-energy state that decays non-radiatively to a lower-energystate, which then emits a second visible photon. Quantitative analysisof the results indicated that LiGdF4:Eu3+ has a quantum efficiency of190%. (R. Wegh et al. 1999 Science 283 663) However, the new phosphoremits primarily red light and equally efficient green and blue phosphorsare still needed to make xenon-based fluorescent lighting a reality.

It is then clear to one of ordinary skill that a rare earth lamp or anyanalogue is not a solid-state lamp and does not enjoy the many benefitsof solid-state lamps. A solid-state lamp in general and a semiconductorsolid-state lamp more particularly do not have a discharge electrode.Further, a rare gas lamp requires vacuum uv to be generated by thedischarge electrode whereas solid-state lighting can operate in thevisible and in the ultraviolet including ultraviolet of lower energy(and higher wavelength) than vacuum ultraviolet. The primary emissiongenerated by the rare gas is from the rare gas itself which is initiallybrought to its excited state, subsequent to which it depopulates theexcited states with emission of light in the vacuum uv, by the transferof the electrical energy generated at the discharge element. (See forexample 1. E. Weintraub; Great Britain Patent GB190324502; 2. Atsushiet. al; Japanese Patent number JP2004091538; issue date Mar. 25, 2004;3. Schoenbach et. al.; Issued United States Patent (US), PublicationU.S. Pat. No. 6,703,771; issue date Mar. 9, 2004; 3. A. Kraus;Publication Number WO03075313, Publication date: Sep. 12, 2003; and 4.Arai, et. al.; Japanese Publication JP2002080843; Publication Date Mar.22, 2002.)

For many years, lighting manufacturers have tried to eliminateelectrodes in fluorescent lamp operation because the emission coating onthe electrodes at each end of a linear lamp deplete over time, which isa major cause of lamp failure and a barrier to longer lamp life. Thishas led to an induction lamp design: Inductively coupled electrodelessfluorescent lamps that last as many as 100,000 hour. These new lamptypes use high-frequency energy to activate the mercury plasma gas andthus the phosphor coating on the lamp's interior surface. This allowsthe electrodeless lamp to restart immediately after a momentary loss ofpower. These lamps maintain operating stability in very coldtemperatures, provide constant light output regardless of supply voltagefluctuations, and offer no shift in color over life. Another type ofinduction lamp currently available for purchase is known as a re-entrantcavity induction lamp, which is available in 55 W, 85 W, and 165 Wmodels that provide 3,500 lumens, 6,000 lumens, and 12,000 lumens,respectively. All models are shaped like an oversized standardincandescent “A” lamp. This lighting system has three separatecomponents: the high-frequency current generator that operates at 2.65MHz, the power coupler that consists of an induction coil wound on aferrite core, and the lamp compartment, which consists of the glass bulbequipped with an internal phosphor coating and a base. A short coaxialcable delivers power from the radio frequency generator to the base ofthe lamp. However, an induction lamp is not a solid-state lamp as anyone can plainly see and all of the benefits of a solid-state lamp arenot available in an induction lamp.

Prior to this present invention, the structure of solid-state lightingwith a p-n junction has had a very limited diversity of functionalforms. (Barnett et. al.; Canadian Patent Application CA 2438889 andrelated U.S. Patent Application 60/270,572, International PublicationNumber WO2002/069409) The plethora of functional forms with lighting ofincandescent and mercury vapor lamps has solved many of the underlyingdeficiencies associated with the light generation from heating filamentsand arc lighting.

What is needed is a semiconductor light-emitting device having improvedlight extraction, improved phosphor conversion, or both and in a mannerthat allows for the use of luminophors in general and organicfluorescers more specifically that may otherwise not degrade instantlyor over a long period of time under constant excitation in a solid-statelight. Prior to the invention presented herein, the structure ofsolid-state lighting with a p-n junction has had very limited diversityof functional form.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows an embodiment of a light emitting diode assemblyconstructed in accordance with the present disclosure.

FIG. 2 shows an embodiment of a light emitting diode assemblyconstructed in accordance with the present disclosure.

FIG. 3 shows an embodiment of a light emitting diode die within anenclosure and a plurality of embodiments of a lighting elementcomprising a light emitting diode.

FIG. 4 shows a plurality of embodiments of a lighting element comprisinga light emitting diode and a down converting element.

FIG. 5 shows an embodiment of a lighting element constructed inaccordance with the present disclosure.

FIG. 6 shows an embodiment of a lighting element constructed inaccordance with the present disclosure.

FIG. 7 shows an embodiment of a lighting element constructed inaccordance with the present disclosure.

FIG. 8 shows an embodiment of a lighting element constructed inaccordance with the present disclosure.

SUMMARY OF THE INVENTION

In one aspect, a microelectronic device is disclosed. Themicroelectronic device includes an outer enclosure enclosing a first gasin a first space, an inner enclosure disposed in the first space of theouter enclosure, at least one elongated elastomeric member disposed inthe inner enclosure, and a plurality of lighting elements embedded inthe at least one elongated elastomeric member.

In another aspect, a method is disclosed. The method includes enclosinga first gas in a first space using an outer enclosure, disposing aninner enclosure in the first space of the outer enclosure, disposing atleast one elongated elastomeric member in the inner enclosure, andembedding a plurality of lighting elements in the at least one elongatedelastomeric member.

The present invention is based on the discovery that a highly efficientachromatic, chromatic and non-visible light emitting device may besimply and economically fabricated utilizing solid state light emittingdiode dies that in the absence of certain elements of the followinggenerates primary radiation which transfers its energy, radiatively, tosecondary luminescent elements where the diode die and or the secondaryluminescent elements are in an enhancing and or protecting enclosure.

The present invention relates broadly to a semiconductor light emittingassembly comprising a solid state device with at least one p-n junctionwhich induces the emission from the solid state device of a firstwavelength radiation to chromatic radiation (radiation, light, luminanceor illuminance with hue), or achromatic radiation (radiation, light,luminance or illuminance) without hue. The solid state device isstructurally associated with a recipient down-converting luminophoricmedium, as hereinafter defined, which when either radiatively orotherwise impinged by the first relatively shorter wavelength radiation,or is otherwise non-radiatively excited, through Forster or Dexterenergy transfer from the excited states that absent the energy transferwould radiatively emit a first relatively shorter wavelength radiation,or the secondary luminescent elements as hereinafter defined within theluminophoric medium are otherwise non-radiatively excited, throughForster or Dexter energy transfer from the excited states that absentthe energy transfer would radiatively emit a relatively shorterwavelength radiation, to responsively emit a secondary radiation,chromatic and achromatic, polarized or unpolarized, in the visible andnon-visible light spectrum. The recipient down-converting luminophoricmedium is protected by virtue of a segregating envelope from elementsthat instantaneously decrease performance or over long term reduceeffectiveness of the down-converting medium. When the segregatingenvelope is constructed to also include the active layer of the solidstate device, the same envelope introduces and maintains a favorableenvironment to maintain, sustain, protect or increase performance of theunderlying semiconductor with a p-n junction where said performance isthe ability to generate light and or to transfer its energynon-radiatively.

In accordance with a specific embodiment of the present invention, anLED operative to emit, for example, monochromatic blue or ultraviolet(UV) radiation is packaged along with fluorescent organic and/orinorganic fluorescers and phosphors—the secondary luminescent elementsin the luminophoric medium—in an insulating or isolating chamber (anassembly), such as a sealed glass ampoule, said package molded withinand suspended within a matrix otherwise protecting the aforementionedassembly. In the case of radiative energy transfer, the monochromaticblue or UV radiation output of the LED is absorbed and then downconverted by the fluorophor or phosphor—the secondary luminescentelements in the luminophoric medium—to yield longer wavelengths toinclude a broad spectrum of frequencies which appear to an observer aswhite light. The atmosphere or in the case of a vacuum, the absence ofatmosphere, within the insulating or isolating chamber is selected so asto increase the probability that the luminophors (the secondaryluminescent elements in the luminophoric medium) required to effect downconversion of light from an LED responsively emit light of secondaryradiation.

This use of an insulating or isolating chamber to enhance the secondaryradiative probability of the fluorescers and/or phosphors to effect downconversion of light from an LED in a solid state light emitting deviceusing a dye or pigment material (a luminophor that fluoresces orphosphoresces; the secondary luminescent elements in the luminophoricmedium) is a significant departure from prior art teaching. In additionto allowing for the generation of achromatic (white) light from a blueor ultraviolet emitting LED die with a typical p-n junction constructionwithout destruction of the luminophors so selected, devices inaccordance with the invention can be variously constructed to provide anessentially infinite series of colored (visible) light emissions, ofeither narrow or broad spectral distribution, from one single p-njunction construction.

As used herein, the term “solid state device,” used in reference to thedevice for generating the primary radiation which subsequently isdown-converted to a longer wavelength radiation in such visibleachromatic (white) or chromatic (color) light spectrum, means a devicewhich is selected from the group consisting of semiconductor lightemitting diodes, semiconductor lasers, thin film electroluminescentcells, electroluminescent display panels, and internal junction organicelectroluminescent devices.

As used herein, the term “primary radiation” means the initial photonsdirectly produced by hole-electron recombination at a p-n junction.

The term “secondary radiation” means the photons subsequently generatedby virtue of transfer of the energy of the excited state that definesthe p-n junction to form some other excited state and the radiation thatis released by virtue of relaxation of this other excited state.

As used herein, the term “luminophoric medium” refers to a materialwhich in response to radiation emitted by the solid state device or isotherwise non-radiatively excited, emits light—achromatic light or colorlight in the visible light spectrum—by fluorescence and/orphosphorescence or emits infra-red light in the non-visible lightspectrum. The term “down-converting medium” is synonymous in our usagewith “luminophoric medium” as the luminophors of interest and discussionherein are those that have a Stokes shift.

As used herein, the term “secondary luminescent elements” refers to thespecific materials that together—whether intimately mixed or not,whether spatially separated or not—comprise the luminophoric medium.

As used herein, the term “chamber” refers to a natural or artificialenclosed space or cavity whose atmosphere can be controlled duringassembly or during use. The term “envelope” is used interchangeably withthe term “chamber.” In certain discussions, the term “secondaryenclosure” is used and is by virtue of my assertion tantamount with howthe term “chamber” and “envelope” is utilized.

As used herein, the term “atmosphere” refers to a surrounding influenceor environment.

As used herein, the term “white light” and “achromatic light” refers tovisible radiation possessing no hue. Achromatic light is free of color;achromatic pigment or dye is a color perceived to have no hue, such asneutral grays. White light is light perceived as achromatic, that is,without hue.

As used herein, the term “colored light” and “chromatic light” refers tovisible light having hue.

As used herein, the term “hue” refers to visible light with theattribute of colors that permits them to be classed as red, yellow,green, blue, or an intermediate between any contiguous pair of thesecolors.

As used herein, the term “tint” refers to a variation of a colorproduced by adding white to it and characterized by a low saturationwith relatively high lightness.

As used herein, the term “shade” refers to the degree to which a coloris decreasingly illuminated; that is, a gradation of darkness for colorlight.

Other aspects, features and embodiments of the invention will be morefully apparent from the ensuing description and claims. This applicationclaims priority from Provisional Application Ser. No. 60/569,007 filed 7May 2004.

DETAILED DESCRIPTION OF THE INVENTION AND PREFERRED EMBODIMENTS THEREOF

The present invention is based on the discovery that a highly efficientlight emitting device may be simply and economically fabricatedutilizing a solid state light emitting diode die that either generatesprimary radiation (acting as a radiative donor) or non-radiativelytransfers energy (acting as a non-radiative donor) from the excitedstate—which defines the p-n junction under an applied voltage—and wherethe diode die (the donor) and or the acceptor of primary radiation andor non-radiative energy transfer is in an enhancing and or protectingenclosure.

Less broadly, the present invention is based on the discovery that ahighly efficient achromatic, chromatic and non-visible light emittingdevice may be simply and economically fabricated utilizing a solid statelight emitting diode die (a donor) approximate to a luminophore medium(an acceptor) that in the absence of certain elements of the followinggenerates primary radiation and where the excited state—which definesthe p-n junction under an applied voltage—transfers its energy,radiatively or non-radiatively, to secondary luminescent elements in theluminophoric medium and where the diode die and or the luminophoricmedium are in an enhancing and or protecting enclosure.

Less broadly, the present invention is based on the discovery that ahighly efficient achromatic, chromatic and non-visible light emittingdevice may be simply and economically fabricated utilizing a solid statelight emitting diode die proximate to a luminophoric medium that in theabsence of certain elements of the following generates primary radiationand where the excited state—which defines the p-n junction under anapplied voltage—transfers its energy, radiatively or non-radiatively, tosecondary luminescent elements in the luminophoric medium and where thediode die and the luminophoric medium are both in the same enhancing andor protecting enclosure.

When the diode die is placed with a protecting and enhancing chamber orenvelope, the diode die is separated from the resin that absent thisinvention completely covers the diode die; further in this embodiment,the protecting and enhancing envelope contains within its internalboundaries material of a gaseous, liquid or solid phase that protectsand enhances the generation of primary light or non-radiative energytransfer from the light emitting diode die. When the luminophoric mediumis placed with a protecting and enhancing chamber or envelope, theluminophoric medium is separated from the resin that absent thisinvention completely covers the diode die; further in this embodiment,the protecting and enhancing envelope contains within its internalboundaries material of a gaseous, liquid or solid phase that protectsand enhances the generation of secondary radiation from the luminophoricmedium itself.

Achromatic light LED solid state devices may be made by the method ofthe present invention. It is preferred that achromatic light if made iseffected is through down-conversion, although there is no requirementthat the invention be limited to generating achromatic light nor is theinvention limited to achromatic light through down-conversion. Ifachromatic light is generated utilizing a down conversion processwhereby an excited state that either generates a primary photon—orotherwise is capable of generating a primary photon absent energytransfer—generated in the active region of the diode, then said primaryradiation is down converted with primary blue emission and/or secondaryblue fluorescent or phosphorescent centers, as well as green and redfluorescent or phosphorescent centers where the fluorescent orphosphorescent centers are within a chamber and are protected by avacuum or a beneficial atmosphere or by some other enhancing effectwithin or impacting the chamber. These fluorescent and or phosphorescentcenters comprise the luminophoric medium. Such an LED device is able todown-convert the relatively monochromatic light, typical of allheretofore monochromatic LED dies and lamps, to a broader emission thatappears as achromatic light from red, green, and blue emission centers.Such a device is also able to enhance the efficiency of generation ofprimary radiation in the absence of luminophors as the beneficialatmosphere augments the generation of primary light by virtue of accessof the beneficial atmosphere to the active layer the defines thesemiconductor p-n junction. As one skilled in the art will immediatelyobserve, the primary photon generated in the active region of the diodemay be a blue photon or an ultraviolet photon, if only one diode die isutilized. There is no requirement that only one diode die be utilized.

Under certain circumstances, it may be desirable for both the lightemitting diode die and the luminophoric medium to be enclosed in thesame chamber, in separate chambers, or only one of the two in a chamber.

When the luminophoric medium contains luminescent elements that emitred, green and blue light, in the case of a uv LED die, or 1) red, greenand blue light; 2) yellow; 3) red, green and yellow, or other suitablecombination of primary and complementary colors in the case of a blueLED die, achromatic light is generated.

When two LED die of different wavelengths are used, for example and uvand a blue LED die, then the luminophoric medium can be optimized togenerate achromatic light by adjusting in concentration or in space thesecondary luminescent elements. It is preferred that the two LED die beof different wavelengths with as large a gap between their respectiveemission wavelength maximum as possible. When a blue LED die and a cyanLED die are used, then the luminophoric medium will contain secondaryluminescent elements that emit in the yellow and in the red. When a uvand green LED die is utilized, then the secondary luminescent elementswill be blue and red; when a blue and red LED die are utilized, then thesecondary luminescent elements will be green. When a blue LED die and ayellow or amber LED die are utilized, then the secondary luminescentelements need only be adjusted to optimize the color temperature of theachromatic light. The invention is not limited to secondary luminescentelements of multiple molecular compositions (for example, a red emitter,a green emitter and a blue emitter) as single component emitters areknown that generate achromatic light when suitably activated. Apreferred white-emitting phosphor comprises zinc sulfide activated withcopper, manganese, chlorine, and, optionally, one or more metalsselected from gold and antimony. A specially preferred phosphor isMn-doped ZnS nano clusters with no less than 5% and no more than 9% Mn,prepared from a colloidal route and where ultraviolet-visible absorptioncurves show that on changing the concentration of Mn2+ ions, there is amaximum in the band gap for an optimum doping (5.5% of Mn), and wherethe fluorescence spectra of the doped clusters consist of two distinctemissions: orange and blue.

It is immediately apparent to a skilled practitioner of the teachingspresented herein that achromatic light may be formed by methods otherthan down-conversion and this invention is not limited to theimplementation of down-conversion for the generation of achromaticlight.

When two light emitting diode dies are utilized at least one must beinternal to the chamber and where the secondary luminescent elementsare, if utilized, internal of external to the chamber, are dependent ofoptimization of the output and durability of the lamp so constructed.When at least one chamber contains only luminescent elements and not asemiconductor die, that chamber just described is replaceable andinterchangeable at will.

When both the diode die and dice are in a chamber and the secondaryluminescent elements are in a chamber, they need not be in the samechamber for radiative energy transfer to take place; they only need tobe in a geometric relationship such that the latter receives the primaryradiation emanating from the diode die or dies.

A significant advantage of organic luminescent materials is theirrelatively broad emission bandwidth that offers the maximal overlap ofphoton wavelengths to most readily generate an achromatic illumination.Prior to this invention, when multiple luminophors were in use (red,green and blue luminophors) it had been most desirable to utilizefluorescent materials with extremely short radiative lifetimes, lessthan 50 nanoseconds, to preclude non-radiative energy transfer (to thelowest energy emitter). However, solid-state lighting requiring anafter-glow, illumination provided after the power supply is shut off, isnot otherwise available since after-glow devices require luminophorswith a lifetime greater than 50 nanoseconds, in fact millisecondlifetimes are more specifically preferred. It is for the most partdesirable that fluorescent materials or phosphorescent materials with aradiative lifetime greater than 50 nanoseconds be spatially separatedwithin a chamber and by virtue thereof, these down-conversionluminophors can continue to provide achromatic or chromatic illuminationafter the power supply is shut off.

It is for the most part desirable that organic fluorescent materials andorganic phosphorescent materials are incorporated within a chamber undervacuum or noble gas or other inert media so as to avoid the opportunityfor oxidation of the luminophoric medium instantaneous to theirexcitation or otherwise degrade the luminophoric medium over an extendedperiod of time. It is also desirable for inorganic or ceramicluminophors to be incorporated within a chamber under vacuum or noblegas or other inert gas or inert liquid or inert solid so as to avoid theopportunity for quenching with any quencher—a gas, liquid or solid notinert. It is recognized by one skilled in the art that the mechanism bywhich gases such as nitrogen, argon, krypton and xenon are utilized inincandescent lamps is different than the mechanism in which it isutilized in this invention and that it has not heretofore beenrecognized, prior to this invention, that gases have a beneficial effectin the long-term totality of lighting from p-n junctions or insolid-state lighting devices. The primary utility of gas in incandescentlighting is related to regeneration of the filament first; the utilityof the gas also relates to convection and conduction of heat and toprevent the vaporization of the underlying filament element and theinert gas preferably contains a regenerative gas which returns materialevaporated from the filament back to the filament. The primary utilityof gas in the invention being claimed herein is the protection of thesecondary luminescent elements within the luminophoric medium from thedeleterious effects of oxygen and other quenchers. The utility of thisinvention is apparent when it is recognized that when gas is utilized inmercury vapor lamps, as opposed to incandescent lamps and or solid-statelamps with a p-n junction, the primary purpose for doing so is forconductive and or convective heat flow to activate the phosphors whichperform better at a higher temperature: Johnson (1984) claimsembodiments in which the phosphor employed exhibits a higher efficiencyat elevated temperatures and the chamber space preferably includes inertgas such as nitrogen or argon so that some convective and/or conductiveheat flow may be provided to the phosphor to permit arc tube to providethe desired operating temperature for the phosphor.

Notwithstanding the primary benefit of the invention being claimedherein, it has heretofore not been recognized that the p-n junction—in aLED lamp—itself will benefit from operating in an environment such asclaimed herein. The prior art shows no examples of LED die lamps, orsolid-state lamps with a p-n junction, whereby the p-n junction used forgeneral illumination lighting is purposely sequestered within a chamberand that the chamber contains gas to enhance the performance of primaryradiation from the p-n junction itself. It is also desirable for thediode die to be incorporated within a chamber or otherwise exposed to anoble or inert gas (or inert liquid or inert solid) whereby the index ofrefraction of the inert media are more closely aligned with the index ofrefraction of the light emitting diode die. A skilled practitioner ofthe art of enhancing light emission in incandescence will note that thebenefit of filament exposure to gas has not been correlated with theindex of refraction of the gas itself although, in incandescent lamps,the index of refraction of solids and the beneficial design thereof, hasbeen noted. (Warren, et. al., 1976, Westinghouse Electric Company;Tschetter et. al., 1985, General Electric Company)

The use of a gas to optimally manage heat, even if said role for the gasis a secondary benefit, in a solid-state lamp with a p-n junction hasnot heretofore been taught. Further, in the specific case where theceramic submount of Lamina are preferred, the method of this inventionallows for said subsmounts to be sequestered within the protecting andenhancing chamber.

In the special case where both the diode die and the secondaryluminescent element are sequestered within the same chamber, it is forthe most part desirable that the chamber that sequesters within it thep-n junction also contain an inert gas or inert liquid or inert solidwith excellent heat conduction if the p-n junction is more sensitive toheat than the luminophors so as to remove heat from the p-n junctionitself. It is preferential that nitrogen or argon be used as kryptonconducts heat less than argon does, and xenon conducts heat less thaneven krypton does. Note that this preferred embodiment is the oppositeof that which is required with incandescence of tungsten filament in asealed light bulb. It is generally the case that when inorganicluminophors are utilized, the heat insensitivity of these inorganicluminophors are such that it is preferred to dissipate the heat awayfrom the p-n junction. In the special case where the light output of theinorganic luminophor requires a high temperature, then it is speciallypreferred to use nitrogen or argon or other gas with excellent heatconductivity.

It is for the most part desirable that the chamber that sequesterswithin it the p-n junction also contain an inert gas or inert liquid orinert solid with poor heat conduction if the p-n junction is lesssensitive to heat than the luminophors so as to preclude heating theluminophors themselves. It is preferential that xenon be used as kryptonconducts heat less than argon does, and xenon conducts heat less thaneven krypton does. It is generally the case that when organicluminophors are utilized, the high heat sensitivity of these organicluminophors is such that it is preferred to not dissipate the heat awayfrom the p-n junction.

Environmental effects, such as available with this invention, onluminescence efficiency—even when quenching or its absence is not afactor—is well known. Effects such as spin-orbit coupling—which enhancemoving between states of different multiplicities and therefore enhancethe efficiency of luminescence when multiplicity changes (i.e.;phosphorescence)—can be effected by the environment that the excitedstate species finds itself in. Sequestering the luminophoric medium thatcontains a phosphorescent luminescent element within a chamber asdescribed herein allows for enhancement of the underlying luminescenceefficiency by introducing a molecule within the chamber that interactswith the luminophors therein and which the molecule has a heavy atomeffect. The heavy atom effect is well known and is the enhancement ofthe rate of a spin-forbidden process by the presence of an atom (forexample bromine) of high atomic number, which is either part of, orexternal to, the excited molecular entity. Mechanistically, it respondsto a spin-orbit coupling enhancement produced by a heavy atom. (IUPACCompendium of Chemical Terminology 2nd Edition (1997), 1996, 68, 2245)

Chromatic light LED solid state devices may be made by the method of thepresent invention. While not necessary to produce chromatic light, it isapparent that the devices of this invention may produce chromatic light,utilizing a down conversion process whereby an excited state that eithergenerates a primary photon or otherwise is capable of generating aprimary photon absent non-radiative energy transfer generated in theactive region of the diode is down converted with primary blue orprimary uv or primary blue and uv emission and/or secondary bluefluorescent or phosphorescent centers, as well as green or redfluorescent or phosphorescent centers where the fluorescent orphosphorescent centers are within a chamber and are protected by avacuum or a beneficial atmosphere or by some other enhancing effectwithin or impacting the chamber. Such an LED device is able todown-convert the relatively monochromatic light; typical of allheretofore colored LED dies and lamps, to a broader emission thatprovides chromatic light from red, green, and blue emission centers. Thesecondary luminescent elements may be selected and varied as desired,with control of concentrations and spatial arrangements of each selectedsecondary luminescent element such that the light generated by theluminophoric medium provides color of any hue and apparent tint.Chromatic light with a strong tint is in fact pale color light,preferred fro general illumination. Chromatic light with a strong shadeis not useful for general illumination but is beneficial for clandestineapplications of lighting and signaling. Such a device for chromaticlight emission, based on down-conversion, requires a LED solid statedevice to generate primary light that is either blue or ultraviolet inemission, or is capable of generating primary light that is either blueor ultraviolet in emission absent non-radiative energy transfer, such asis available using blue or ultraviolet LED dies and lamps. It is animportant element of this consideration that either inorganic or organicfluorescent or phosphorescent materials can be utilized to down-convertthe primary ultraviolet or blue light emission to a mixture of blue,green and red luminescent emissions. A significant advantage of organicluminescent materials is their relatively broad emission bandwidth whichoffers the maximal overlap of photon wavelengths to most readilygenerate a chromatic illumination. Further, it is most desirable toutilize organic fluorescent material with extremely short radiativelifetimes, less than 50 nanoseconds, to preclude non-radiative energytransfer (to the lowest energy emitter) since an after-glow is notdesired in this particular embodiment. It is for the most part desirablethat organic fluorescent materials and organic phosphorescent materialsare incorporated within a chamber under vacuum or noble gas or otherinert media so as to avoid the opportunity for oxidation of theluminophoric medium instantaneous to their excitation or over anextended period of time.

A significant part of certain inorganic phosphors is that they canabsorb more than one photon prior to radiatively relax to their groundstate. This is preferred in the case of solid-state lighting of thedesign described herein for this invention and where it is observed asaturation of the primary photon absorption. In this particular case, itis preferred to maximally down-convert the primary photons, even thoughtthe observed saturation occurs with most ceramic phosphors utilizedheretofore. It is especially preferred then to use a ceramic phosphorthat can absorb more than one photon and it is especially preferred thatthis occur with luminophors of extremely long lifetime. An excellentceramic phosphor with extremely long lifetime is SrAl2O4 phosphors dopedwith Eu and Dy. In a preferred embodiment, the phosphor so identified inthe immediately preceding sentence is coated on the interior walls ofthe chamber, using dispersion in a binder, and after the film is dried,the layer of selected phosphor is capable of absorbing multiple photonswhile immobilized within the desired chamber. The phosphors may also becoated on the sapphire substrate in which a GaN on sapphire LED isconstructed. The phosphors may also be added to a previously evacuatedchamber within in which a LED die has already been assembled and wheredispersion of the material is enhanced by the vacuum itself.

As discussed above, there have been disclosures regarding the generationof white light in solid state semiconductor devices with p-n junctionsusing radiative energy transfer and these examples use primarilyinorganic dopants near the active layers of the p-n junctions or organicfluorescers within the epoxy matrix encapsulating the semiconductor, butnone are known that apply the principles of the present invention tosemiconductor based p-n junction LED lamps. It has not been heretoforerecognized than organic luminophors can acts as dopants andnon-radiative energy transfer will populate the excited states of theseluminophors when so arranged to generate secondary radiation. Absent theinvention described herein, the utilization of an isolating andprotecting chamber, said non-radiative energy transfer is not effective.As an example, benzophenone is frequently used as a triplet sensitizerusing the mechanism of Dexter energy transfer previously described.Benzophenone when excited enters a singlet excited state and then ratherrapidly crosses over into its triplet excited state through a processknown to those skilled in the art as intersystem crossing. Oncebenzophenone triplet is formed—an excited state species that is easilyquenched by the ground state of oxygen, itself a triplet, rendering theprocess sough after basically useless—it can transfer its energynon-radiatively to the ground state (typically a singlet) of aluminophor such as bis(phenylethynyl)anthracene to form the excitedtriplet state of bis(phenylethynyl)anthracene which is then able tophosphoresce. There is no other means of practically garnering theexcited triplet state of bis(phenylethynyl)anthracene other than throughnon-radiative energy transfer since radiative energy transfer onlypopulates the singlet excited state and the efficiency of intersystemcrossing from the singlet excited state to the triplet excited state inbis(phenylethynyl)anthracene is essentially zero. However, as mentioned,triplet benzophenone is easily quenched by oxygen and tripletbenzophenone is excellent at destroying through hydrogen abstraction theepoxy resin used normally in potting a LED lamp. Therefore, theinvention herein described which includes among its elements aprotecting and enhancing chamber, allows for immobilization ofbenzophenone within the isolating and protecting chamber, isolation andprotection of benzophenone triplets so formed from quenching by eitheroxygen or hydrocarbons such as epoxy resin, and non-radiative energytransfer from the protected benzophenone triplet to a luminophor withthe emission requirements required to form chromatic, achromatic ornon-visible light emission.

Referring now to the drawings, FIG. 1 shows an achromatic or chromaticor infra-red light emitting diode assembly 10 constructed in accordancewith the invention. This assembly comprises an enclosing wall 7 defininga light-transmissive enclosure 11 having an interior volume therewithin. The enclosure 11 may be formed of any suitable material having alight-transmissive character, such as a clear or translucent polymer, ora glass material. A second light-transmissive enclosure 111—which is thechamber or envelope of this invention—houses in its interior volume alight emitting diode (LED) die 13 positioned on support 14. First andsecond electrical conductors 16 and 17 are connected to the emitting andthe rear faces 18 and 19 of LED die 13, respectively, and with theemitting face 18 of the LED die coupled to the first electricalconductor 16 by lead 12. The second enclosure 111 contains at least onelight emitting diode die and reflective supports and is filled with asuitable down-converting material 20, e.g., a down-converting medium orluminophoric medium comprising fluorescent and or phosphorescentelements (component(s), or mixtures thereof)—for example a luminophoricmedium coated on the interior wall 112 of the secondary enclosure 111,which functions to down convert the light output from face 18 of LED 13or reflecting off of surface 12 on which LED 13 rests to achromatic orchromatic or infra-red light. The down-converting medium need not becoated on the interior wall 112 of the secondary enclosure 111 but needonly be within the outer wall of the secondary enclosure 111. Thedown-converting medium may be dispersed inside the second enclosure andnot be attached, physically nor chemically to the interior wall. Thesecond light-transmissive enclosure 111 is under vacuum or is filledwith a medium that enhances, instantaneously or over the long term,primary radiation generated by the light emitting diode (LED) die 13 andor enhances, instantaneously or over the long term, the quantity andquality of secondary radiation generated by the luminophoric medium, andor enhances, instantaneously or over the long term the radiative ornon-radiative energy transfer from the excited state in the active layerof the LED die 13 to the luminophoric medium. The active layer of thelight emitting diode die is permanently within the space formed by thesecondary enclosure and the reflecting posts onto which the lightemitting diode die rests is also contained in the interior volume of thesecondary enclosure. Note that luminophor may be coated on the externalwall 113 of the secondary enclosure 111; in that case, however, theluminophor does not enjoy any additional benefit from the protecting andenhancing material enclosed within the secondary enclosure and is, infact, in intimate contact with resin media 21. The material sequesteredwithin the second enclosure 111 protects and enhances the emission ofprimary light as well as secondary light in contrast to gas sequesteredwithin incandescent lamps which primarily regenerate the incandescentfilament.

In one embodiment, the second enclosure 111 is filled with a gaseousmedium that is inert such as argon gas and otherwise limits theoxidation or other means of bimolecular and unimolecular degradation ofthe luminophoric medium which contains fluorescent centers. Solely forthe purpose of manufacturing, a dense inert gas such as argon ispreferred so that when sealing the second enclosure, air ispreferentially kept out of the enclosure and argon is preferably keptinside of the enclosure. However, techniques for sealing chambers of thetype presented herein, with inert gases and electrical leads permeatingthrough an enclosure, such as a glass enclosure is well known andpracticed.

In one embodiment, the second enclosure 111 is filled with a gaseousmedium that is inert such as argon gas and otherwise prevents thequenching of the excited state of a phosphorescent component of theluminescent medium that provides secondary radiation after excitation byeither primary radiation or non-radiative energy transfer.

In another embodiment, the second enclosure 111 is filled with agaseous, liquid or solid medium and whereby the medium, whethercompletely inert or not, is selected solely for the basis of its indexof refraction so that the selected medium has an index of refractionthat maximizes the projection of primary radiation and or secondaryradiation. Without any intention of limited the full range of materialsthat can be utilized to practice my invention, we claim the use of thefollowing environment as operable environments when consideration ofindex of refraction is the most important consideration: in the seriesof vacuum, helium, argon, krypton, xenon, benzene, epoxy, carbondisulfide, sapphire, flint glass with 81% lead, cubic zirconia, GaN, andcrystal iodine the index of refraction changes from 1.00, 1.00, 1.00,1.29 (liquid), 1.38 (liquid), 1.501, 1.545, 1.63, 1.76, 1.805, 2.173,2.45, and 3.340. The index of refraction roughly correlates with thedensity of the material; for organic molecules, the greater the highhalogen content, the greater the density and the greater the index ofrefraction. Hence, methylene iodide has roughly the same index ofrefraction as sapphire (1.74 for the former vs. 1.77 for the latter),whereas iodobenzene and iodonapthalene have refractive indices of 1.62and 1.704, respectively. Solid medium of utility are zinc oxide (indexof refraction of 2.02) antimony oxide (index of refraction of 2.09 to2.29) zinc sulfide (index of refraction of 2.37), zirconium oxide (indexof refraction of 2.40), rutile titanium oxide (index of refraction of2.70). Many materials that are capable of having high index ofrefraction have heavy atoms that also enhance spin-orbit coupling. Manyorganic polymers that are opaque to x-rays and do not degrade as aresult of x-ray irradiation have heavy elements and as a result areinert solids in the context of this invention; moreover these inertsolids with heavy elements have a high index of refraction.

In another embodiment, the second enclosure 111 is filled with agaseous, liquid or solid medium and whereby the medium, whethercompletely inert or not, is selected solely for the basis of itsdispersion so that the selected medium has a low degree of dispersion ofblue, green and red photons so that the achromatic light so formed doesnot appear to be subsequently dispersed back into their relativecomponents.

In one embodiment, the secondary enclosure is filled with a liquidsolvent that solubilizes the down-converting medium. In anotherembodiment, the secondary enclosure is filled with a polymeric resinother than an epoxy resin that normally pots a light emitting diode dieand within which the down-converting medium is dispersed, solubilized orotherwise suspended.

In one embodiment, the second enclosure is filled with a solid inactivematrix, such as a zeolite or a cyclodextrin that sequesters individualmolecules of fluorescent components and otherwise limits bimoleculardegradation of the fluorescent components. The secondary luminescentelement is physically or chemically adsorbed to the zeolite cavity or isotherwise sequestered with a cyclodextrin cavity adopting themethodology of sequestering organic dyes in nanoporous zeolite crystals.(Irene L. Li, Z. K. Tang, X. D. Xiao, C. L. Yang, and W. K. Ge, AppliedPhysics Letters Vol 83(12) pp. 2438-2440. Sep. 22, 2003) Organic:ceramichybrids may be used within the enclosure. In one embodiment, the organicluminophor such as a Lumogen derived diimide organic fluorescer isphysically immobilized or covalently attached to a otherwisenon-luminescent garnet aluminate structure such as an undoped yttriumaluminum garnet or to a doped yttrium aluminum garnet. In anotherembodiment, the organic fluorescer is immobilized within a xerogel withpores of less than 100 Angstroms. (Design of hybrid organic-inorganicmaterials synthesized via sol-gel chemistry by C. Sanchez and F. Ribot,New J. Chem., 18, 1007-1047 (1994); Hybrid organic-inorganic materials:The sol-gel approach by J. D. Mackenzie, in Hybrid Organic-InorganicComposites, pp. 226-236 (1995)) In another embodiment, the dye Rhodamineis immobilized within a silica—zirconia material. In another embodiment,the selected organic luminescent dyes—Crystal Violet (CV) and MalachiteGreen (MG)—are incorporated and immobilized into a polyphosphate gel.(1. DEL NERO, Jordan, GALEMBECK, André, SILVA, Sidicleia Bezerra Costaet al. Dye incorporation in polyphosphate gels: synthesis andtheoretical calculations. Mat. Res., April/June 2003, vol. 6, no. 3, p.335-340. ISSN 1516-1439. 2. Electronic Document Format (ISO). DEL NERO,Jordan, GALEMBECK, André, SILVA, Sidicleia Bezerra Costa et al. Dyeincorporation in polyphosphate gels: synthesis and theoreticalcalculations. Mat. Res. [online]. April/June 2003, vol. 6, no. 3 [cited16 Oct. 2004], p. 335-340. Available from World Wide Web:<http://www.scielo.br/scielo.php?script=sci_arttext&pid=S1516-14392003000300006&Ing=en&nrm=iso>.ISSN 1516-1439.) In another embodiment, organic fluorescent dye in thehigher index of refraction material zirconia may be used. (E. Giorgetti,G. Margheri, S. Sottini, M. Casalboni, R. Senesi, M. Scarselli and R.Pizzoferrato, “Dye-doped Zirconia-based Ormosil planarwaveguides:optical properties and surface morphology”, J. Non-Cryst.Solids, 255, 193 (1999). See also D. B. Mitzi, K. Chondroudis, and C. R.Kagan, “Organic-inorganic electronics”, IBM Journal of Research andDevelopment, Volume 45, Number 1, 2001.)

In one embodiment, the secondary enclosure is glass ampoule produced ona standard ampoule filling and sealing machine.

In one embodiment, LED 13 comprises a leaded, gallium nitride based LEDwhich exhibits blue light emission with an emission maximum atapproximately 450 nm with a FWHM of approximately 65 nm. Such a deviceis available commercially from Toyoda Gosei Co. Ltd. (Nishikasugai,Japan; see U.S. Pat. No. 5,369,289) or as Nichia Product No. NLPB520,NLPB300, etc. from Nichia Chemical Industries, Ltd. (Shin-NihonkaikanBldg. 3-7-18, Tokyo, 0108 Japan; see Japanese Patent Application 4-321,280).

In one embodiment, the down-converting material on the interior of thesecond enclosure 111 comprises three luminophors, mixed together to forma uniform mixture: a blue fluorescer (Lumogen® F Violet 570—substitutednapthalenetetracarboxylic diimide), a green-yellow fluorescer (Lumogen®F Yellow 083—substituted perylenetetracarboxylic diimide) and a redfluorescer (Lumogen® F Red 300—substituted perylenetetracarboxylicdiimide). A composition comprising such blue, green-yellow, and redfluorescent materials, all organic based, as incorporated in chamber111, is available commercially from BASF Pigment Division.

In one embodiment, the down-converting material is spatially separatedon the interior of the second enclosure 111 and the separate threeluminophors are: a blue fluorescer (Lumogen® F Violet 570—substitutednapthalenetetracarboxylic diimide), a green-yellow fluorescer (Lumogen®F Yellow 083—substituted perylenetetracarboxylic diimide) and a redfluorescer (Lumogen® F Red 300—substituted perylenetetracarboxylicdiimide). A composition comprising such blue, green-yellow, and redfluorescent materials, all organic based, as incorporated in chamber111, is available commercially from BASF Pigment Division.

In one embodiment, the spatially separated materials are printed ontothe interior wall using an ink-jet printer; the three luminophors are: ablue fluorescer (Lumogen® F Violet 570—substitutednapthalenetetracarboxylic diimide), a green-yellow fluorescer (Lumogen®F Yellow 083—substituted perylenetetracarboxylic diimide) and a redfluorescer (Lumogen® F Red 300—substituted perylenetetracarboxylicdiimide). A composition comprising such blue, green-yellow, and redfluorescent materials, all organic based, as incorporated in chamber111, is available commercially from BASF Pigment Division.

One or ordinary skill will immediately acknowledge from the teachingspresented herein that co-mingling multiple luminophors or physicallyseparating them, preferable by ink-jet printing of solutions of theluminophors and curing thereafter, is not limited to the Lumogenfluorescers presented herein in the preceding paragraphs but can beeffected with organic luminophors and inorganic luminophors.

In one embodiment, the down-converting material on the interior of thesecond enclosure 111 comprises a blue fluorescer (Lumogen® F Violet570—substituted napthalenetetracarboxylic diimide), a green-yellowfluorescer (Lumogen® F Yellow 083—substituted perylenetetracarboxylicdiimide) and a red fluorescer (Lumogen® F Red 300—substitutedperylenetetracarboxylic diimide). At the same time, on the exterior wall113, of the second enclosure 111 is coated an inorganic phosphor such asCe3+ doped yttrium aluminum garnet. A composition comprising such blue,green-yellow, and red fluorescent materials, all organic based,incorporated within chamber 111, is adjusted by virtue of adjusting theconcentration of materials, to match the CIE coordinates of theinorganic Ce3+ doped yttrium aluminum garnet film on the outer wall ofthe second enclosure 111. In this manner, the operational performance ofthe solid-state device is prolonged by virtue of two identicalluminescent elements of differing operations but identical photopicresponse.

In one embodiment, the ceramic phosphor written asRe3(Al1-sGas)5O12:Ce:xMAl2O4 wherein Re is a rare earth selected fromthe group consisting of yttrium, gadolinium, and ytterbium; s is equalto or greater than 0 and less than or equal to 1; x is 0.01 to about1.0%; and M is an alkali or alkaline earth metal is suspended as anemulsion with a polymerizable binder such as polyvinyl alcohol or morepreferred polyvinylpyrrolidone-polyvinyl alcohol. A fixed amount of thephosphor-binder material is applied to the inner wall of the chamber andthe binder is then polymerized to form a robust phosphor thin filmdirectly on the inner wall. Polymerization can be carried out usingphoto-initiation or thermally induced polymerization subsequent to whichthe chamber is used to assemble the LED lamp. Thus the present inventionincludes using two-phase phosphors; a method of applying these two-phasephosphors to the chamber that coats the inner surface of the chamber andwhich said chamber is ultimately containing a vacuum or a gas selectedfrom ammonia or other Lewis base, nitrogen, argon, xenon, and or kryptonto make a LED lamp to produce achromatic light.

In one embodiment, the ceramic phosphor written asRe3(Al1-sGas)5O12:Ce:xMAl2O4 wherein Re is a rare earth selected fromthe group consisting of yttrium, gadolinium, and ytterbium and where thecomposition and structure of the ceramic phosphor is determined by magicangle spinning NMR as opposed to electron dispersive X-Ray (EDX)analysis which, when carried out, yields at best an elementalcomposition but not the actual chemical structure of the luminescentmaterials; s is equal to or greater than 0 and less than or equal to 1;x is 0.01 to about 1.0%; and M is an alkali or alkaline earth metal issuspended as an emulsion with a polymer binder such as polyvinyl alcoholor more preferred polyvinylpyrrolidone-polyvinyl acetate and applied tothe inner wall of the chamber as already described. A suspension oftitanium dioxide is applied to the outer wall of the chamber andsimilarly polymerized to form a robust scattering layer; subsequent towhich the chamber is used to assemble the LED lamp. Thus the presentinvention includes using two-phase phosphors; a method of applying thesetwo-phase phosphors to the chamber that coats the inner surface of thechamber and which said chamber is ultimately containing a vacuum or agas selected from ammonia or other Lewis base, nitrogen, argon, xenon,and or krypton to make a LED lamp, with scattering particles therein toproduce achromatic light emanating from a Lambertian surface.

In one embodiment, a protective layer comprising Al₂O₃, Y₂O₃ or arare-earth oxide should be applied between the inner side of the chamberand the phosphor layer.

In one embodiment, the down-converting material on the interior of thesecond enclosure 111 comprises a blue fluorescer (Lumogen® F Violet570—substituted napthalenetetracarboxylic diimide), a green-yellowfluorescer (Lumogen® F Yellow 083—substituted perylenetetracarboxylicdiimide) and a red fluorescer (Lumogen® F Red 300—substitutedperylenetetracarboxylic diimide). At the same time, on the exterior wall113, of the second enclosure 111 is coated an inorganic phosphorescentphosphor such as the spinel europium doped strontium aluminateSrAl2O4:Eu. A composition comprising such blue, green-yellow, and redfluorescent materials, all organic based, incorporated within chamber111, is adjusted by virtue of adjusting the concentration of materials,to match the CIE coordinates of the inorganic europium doped strontiumaluminate film on the outer wall of the second enclosure 111. In thismanner, the operational performance of the solid-state device isprolonged by virtue of two identical luminescent elements of differingoperations but identical photopic response. Further, with removal ofelectrical current the excited states of spinel europium doped strontiumaluminate SrAl2O4:Eu continues to provide chromatic illumination.

In one embodiment, the down-converting material on the interior of thesecond enclosure 111 comprises a ceramic phosphor such as Ce3+ dopedyttrium aluminum garnet film on the inner wall of the second enclosure111. At the same time, on the exterior wall 113, of the second enclosure111 is coated an inorganic phosphorescent phosphor such as the spineleuropium doped strontium aluminate SrAl2O4:Eu. In this manner, theoperational performance of the solid-state device is prolonged by virtueof two identical luminescent elements of differing operations. Further,with removal of electrical current the excited states of spinel europiumdoped strontium aluminate SrAl2O4:Eu continues to provide green oryellow-green chromatic illumination.

In one embodiment, the down-converting material on the interior of thesecond enclosure 111 comprises a ceramic phosphor such as Ce3+ dopedyttrium aluminum garnet film on the inner wall of the second enclosure111. At the same time, on the exterior wall 113, of the second enclosure111 is coated an inorganic phosphorescent phosphor such as the strontiumsulfide (SrS) activated with divalent europium or SrS:Eu doped with anytrivalent rare earth ions, such as holmium (Ho), erbium (Er), neodymium(Nd) and the like. In this manner, the operational performance of thesolid-state device is prolonged by virtue of two identical luminescentelements of differing operations. Further, with removal of electricalcurrent the excited states of strontium sulfide continues to provide redchromatic illumination.

Both gallium nitride and silicon carbide LEDs are suitable forgenerating light at appropriate wavelengths and of sufficiently highenergy and spectral overlap with absorption curves of thedown-converting medium. In the case where radiative energy transfer isimplemented, the LED preferably is selected to emit most efficiently inregions where luminescent dyes may be usefully employed to absorbwavelengths compatible with readily commercially available fluorescersand/or phosphors for down conversion to achromatic or chromatic light.In the case where non-radiative energy transfer between the excitedstate of the hole-electron recombination and the ground state of theluminophors in the luminophoric medium is implemented, the LEDpreferably is selected to allow the wavefunctions that define theexcited states formed by hole-electron recombination to integrallyoverlap with the wavefunctions that define the excited states of thefluorescers and or phosphors used in the luminophoric medium. In thecase where non-radiative energy transfer between the excited state of atleast one luminophor in the luminophoric medium, a luminophor of thefirst kind, and the ground state of at least one other luminophor in theluminophoric medium, a luminophor of the second kind, is implemented,the luminophor of the first kind preferably is selected to allow thewavefunctions that define the excited state of the luminophor of thefirst kind to integrally overlap with the wavefunction that defines theexcited state of the fluorescers and or phosphors used as the luminophorof the second kind.

The luminophoric medium utilized in the light emitting assembly of thepresent invention thus comprises a down-converting material which mayinclude suitable luminescent dyes which absorb the radiation emitted bythe LED or other solid state device generating the primary radiation, tothereby transfer the radiation energy to the fluorescer(s) and/orphosphor(s) for emission of white light. Alternatively, the luminophoricmedium may comprise simply the fluorescer(s) and/or phosphor(s), withoutany associated mediating material such as intermediate luminescent dyes,if the fluorescer(s) and/or phosphor(s) are directly excitable to emitthe desired white light. It is preferential that at least portions ofthe luminophoric medium be enclosed with second enclosure 111 althoughcertain elements of the luminophoric medium may be external to thesecond enclosure as long as some of the luminophoric medium is internalto the second enclosure.

The light emitting assembly shown in FIG. 2, has the same generalstructure as is shown in FIG. 1 (with the same reference numerals ofcorresponding parts for ease of reference), but in place of thesemiconductor support being placed within the second enclosure 111, thesemiconductor support—but not the semiconductor itself—is external tothe second enclosure 111 and therefore also supports the placement ofthe secondary enclosure. In this embodiment, illustrated in FIG. 2, thelight emitting assembly utilizes a fluorescer within the secondenclosure 111 that is responsively and radiatively excited by theprimary photons from the semiconductor p-n junction. The fluorescer insuch embodiment may be either covalently or non-covalently attached tothe inner wall 112 of the second enclosure, or sequestered within thestructural form itself that defines the wall of the second enclosure1111, and/or coated as an interior film of the fluorescer on theinterior wall surface of the housing wall 112. Alternatively, thefluorescer may be in solution and sequestered within the sealed innerchamber of the second enclosure 111 or dispersed in a glass or polymericmatrix sealed sequestered within the sealed inner chamber of the secondenclosure, and/or in the vapor state and sequestered within the sealedinner chamber of the second enclosure 111. The material sequesteredwithin the second enclosure 111 protects and enhances the emission ofprimary light as well as secondary light in contrast to gas sequesteredwithin incandescent lamps which primarily regenerate the incandescentfilament. The luminophoric medium may also be physically or chemicallyattached to the substrate of the diode die or to exposed active layerregions of the die itself.

Comparing the structures of the FIGS. 1 and 2 assemblies, it is seenthat the semiconductor support in the FIG. 1 embodiment is contiguouslyarranged about the LED die structure in the interior volume of thehousing, while the semiconductor support in the FIG. 2 embodiment isdisposed in spaced relationship to the LED die structure. It will beapparent that the specific arrangement of the solid state device such asLED 13, relative to the down-converting medium of the assembly andsupports, may be widely varied in the broad practice of the invention,it being necessary only that the solid state device functioning as thesource of the primary shorter wavelength radiation be in transmittingrelationship to the recipient luminophoric medium, so that the latterfunctions in use to down-convert the transmitted radiation from thesolid state device and responsively thereto emit achromatic light orchromatic light or infra-red light. When the luminophoric medium isdistant from the active layer of the p-n junction by more than 50Angstroms, then only radiative energy transfer is operable andnon-radiative energy transfer is not possible. In that the inventiondescribed in FIG. 2 is not all that different than the implementationdescribed in FIG. 1, it is clear from the previous teachings that manydifferent luminophors and secondary luminescent elements may be used andthat two diode die may be used as well as one. Therefore, for the sakeof simplification but not to otherwise limit the scope of thisinvention, we will limit our discussion of all the embodiments availablewhen FIG. 2 represents the implementation of this invention better thanFIG. 1 and refer those of ordinary skill to the teachings alreadyutilized to describe embodiments of this invention represented by FIG.1.

In FIG. 3, the placement of the light emitting diode die within thesecondary enclosure 111 is more noticeably described. In this preferredembodiment, the luminescent medium is attached to the inner wall of thesecondary enclosure 111 and or to the alumina (sapphire) substrate thatdefines the diode die. The physical location of dyes or fluorescersspecifically formulated into the luminophoric medium internal to thechamber or cavity, which may for example include a ceramicnon-luminescent dispersant in which the organic dyes and/or fluorescersare adsorbed and or otherwise dispersible, is not specifically limited,and fitting amount(s) of suitable material(s) for such purpose can bereadily determined without undue experimentation, to provide goodachromatic, or chromatic light emission (of virtually any tint or hue),as well as a virtually infinite series of chromaticity for all visiblehues. In FIG. 3 and in a preferred embodiment, without limiting thescope of this invention, the down-converting medium is covalentlyattached to the inner wall of the secondary enclosure 111. In theembodiment where the luminophoric medium is covalently attached to thelight emitting diode die as opposed to the inner wall of the secondaryenclosure and is immobilized as such to be within 50 Angstroms of theactive region of said diode die, then non-radiative energy transfer isaffected and down-conversion occurs without the requirement of radiativeenergy transfer. The preferred embodiment of the implementation of thisinvention as described by FIG. 3 is for a gas to be sequestered withinthe enclosure and for the gas to protect and enhance the primaryradiation emanating from the p-n junction and or the secondaryluminescent elements. When achromatic light is the desired output of thedevice described by FIG. 3, down-conversion is the preferredimplementation method for generation of achromatic light withdown-conversion described completely in this invention and in others.However, the full scope of this invention is not contingent ondown-conversion being the sole method of implementation for achromaticlight and the invention is still operable regardless of whether thesecondary luminescent elements are present in FIG. 3 and regardless ofwhether achromatic light is the result there from. It is clear that thedevice is operable absent the secondary luminescent element and that thedevice is operable when chromatic light is the desired and resultantoutput. However, one of ordinary skill will note, from the completeteachings of this invention presented herein that the device describedin FIG. 3 may contain two diode die and that the secondary luminescentelements may be activated not by down-conversion but by otherprocesses—thermo-luminescence and electro-luminescence being twoparticular implementations. When the immobilized and covalently attachedsecondary luminescent elements are activated by an applied electricfield, contacts need to be provided to the secondary luminescentelements although said contacts are not shown in the FIG. 3 for sake ofsimplicity. Regardless of the mechanism by which a secondary luminescentelement is activated, the medium inside the enclosure that provides aprotecting and enhancing effect is preferred to be a gas, but need notbe matter solely of the gaseous state. If a gas, then it is preferredthat the gas protect and enhance by exclusion and reduction of oxidativesteps which would otherwise degrade and or quench the secondary lightemission? For reasons previously taught, it is preferred that the gas benitrogen, argon, krypton and or xenon and or mixtures thereof. Theprotecting and enhancing gas may include other gaseous elements thatprotect and enhance not only the secondary luminescent elements but thep-n junction and the mechanism by which primary light is generated.

An ultraviolet LED light source suitable for use in the structure ofFIG. 1 or FIG. 2 or FIG. 3 may comprise: aluminum gallium indiumnitride; aluminum gallium nitride; indium gallium nitride; galliumnitride or any other ultraviolet emitting diode. A blue LED light sourcemay be based on: indium gallium nitride; silicon carbide; zinc selenide;or any other blue light emitting diode source.

TBP, Coumarin-6 and DCM-1, as described by Kido et al. in EuropeanPatent EP 647694, are suitable materials for down conversion of theoutput of gallium nitride or silicon carbide LEDs. Gallium nitride andits alloys can emit in the spectral range covering the blue andultraviolet extending from wavelengths of 200 nanometers toapproximately 650 nanometers. Silicon carbide LEDs emit most efficientlyin the blue at wavelengths of around 470 nanometers.

If gallium nitride emitters are employed, preferred substrates for theemitters include silicon carbide, sapphire, gallium nitride and galliumaluminum indium nitride alloys, and gallium nitride-silicon carbidealloys, for achieving a proper lattice match. If gallium nitrideemitters are employed, the fluorescent and phosphorescent centers may becovalently linked to the substrate surface. If sapphire is thesubstrate, non-covalent chemical and physical adsorption of thefluorescent and or phosphorescent centers to the sapphire substrate maybe preferentially employed. If desired or if covalent linkage and orchemical and physical adsorption of the fluorescent and orphosphorescent centers to the substrate on which the gallium nitridedevice is constructed is disadvantageous, then another layer, such as asilicon dioxide layer may be applied to the substrate or to the galliumnitride so as to provide a platform for the covalent, chemical orphysical adsorption of the fluorescent and or phosphorescent centers.

With ultraviolet or blue light LEDs, aromatic fluorescers may beemployed as down-converting emitters. By way of example, suitablefluorescers could be selected from:

1) blue luminescent compositions—9,10-diphenylanthracene;1-chloro-9,10-diphenylanthracene; 2-chloro-9,10-diphenylanthracene;2-methoxy-9,10-diphenylanthracene; Lumogen® F Violet 570 (a substitutednapthalenetetracarboxylic diimide); Alq2OPh (were Al is aluminum, q is8-hydroxyquinolate, and Ph is phenyl);

2) green-yellow luminescent compositions—9,10-bis(phenylethynyl)anthracence; 2-chloro-9,10-bis(phenylethynyl)-anthracene; Coumarin-5(7-diethylamino-3-(2′benzothiazoyl-)coumarin); Lumogen® Yellow 083 (asubstituted perylenetetracarboxylic diimide); and Mq3 (where M is aGroup III metal, such as Al, Ga or In, and q is 8-hydroxyquinolate); and

3) red-orange luminescent materials—DCM-1; Lumogen® F Red 300 (asubstituted perylenetetracarboxylic diimide); Lumogen® F Orange 240 (asubstituted perylenetetracarboxylic diimide); tetraphenylnapthacence;zinc phthalocyanine; [benzoythiazoylidene)methyl]squaraines;tris(bipyridine-ruthenium)2+; and [3]-catenand complexes with copper.

When luminescent dyes are required that emit towards the red and whichare capable of being excited non-radiatively as described more fullyelsewhere in my present invention, the dyes may include so-called CyDyesfrom GE Healthcare: (Fluorophore, Color of fluorescence, AbsorptionMaximum, Emission Maximum)—Cy3, Orange 550 nm, 570 nm; Cy3.5, Scarlet,581 nm, 596 nm; Cy5, Far-red, 649 nm, 670 nm; and Cy5.5, Near IR, 675nm, 694 nm. The Alexa Fluor series of dyes from Invitrogen nay also beused as many have absorption maxima near the maximum of primaryradiation emanating from GaN semiconductors. More specifically the dyeAlexa Fluor® 430 carboxylic acid, succinimidyl ester my be used tocovalently attach to suitably prepared ceramic media and or glass wallenclosures (e.g.; amine derivatized) and where said dye absorbs bluelight with one maximum at 450 nm. The dye may be used to form aderivatized yttrium aluminum garnet without undue experimentation suchthat the new composition of matter contains both an inorganicluminescent element, such as a cerium dopant, and an organic luminescentelement.

The luminophoric medium may or may not exist external to the chamber atthe same time the luminophoric medium is internal to the chamber. Themedium in which the fluorescent and or phosphorescent centers that areexternal to the chamber may include a polymeric matrix or any othermatrix and need not be identical to the medium of the luminophoricmedium internal to the cavity or chamber. When the external luminophoricmedium contains a ceramic phosphor, it is preferential that the ceramicphosphor be a yttrium aluminum garnet phosphor in general or a Ce3+doped yttrium aluminum garnet more specifically and that the internalluminophoric center contain, at the same time, a green luminescentfluorescers such as 9,10-bis(phenylethynyl) anthracene. When it isdesirable that Ce3+ doped yttrium aluminum garnet be used in intimatecontact with 9,10-bis(phenylethynyl) anthracene, then both luminophors,or a new composition of matter that contains the covalent addition ofthe anthracene to the active oxygen of garnet or other ceramicphosphors, or related chemical and physical adsorption of the former tothe latter, are preferentially sequestered within the sealed secondenclosure 111.

Even more preferred is to covalently attach an organic fluorescer, suchas pyrene, to an inert solid matrix that protects the organicfluorescer, such as a zeolite or if it is preferred that the solidmatrix emits light, cerium doped yttrium aluminum garnet. Pyrene with achemical linker arm such as hexamethylene bromide reacts with aluminumoxide based luminophors such as anhydrous cerium doped yttrium aluminumgarnet or strontium aluminate to form a new composition of matter:pyrene-(CH2)6-YAG:Ce3+.

In one embodiment, cerium doped yttrium aluminum garnet preparedaccording to a well known method used by many practitioners (Wang et.al., U.S. Pat. No. 6,717,349) is suspended in organic solvent and ared-orange derivative of Lumogen® F Red 300—derivatized with amethyleneacylchloride or like linker arm—is suspended in the samesolvent. After a suitable period of time to insure that all of thecerium doped yttrium aluminum garnet is covalently attached to theLumogen® F Red 300 luminophor with a CH2-CO— linker arm molecularlyinserted thereto, and where the linker arm is incorporated into theLumogen® F Red 300 with out undue experimentation (See for example,linker arm procedures as in Reynolds, et. al.; Canadian PatentApplication CA 2089087; also M. J. Heller, Canadian Patent ApplicationCA 2123133. An excellent reference for “like linker arm” can be found inWaggoner, et. al.; U.S. Pat. No. 6,673,943; issued date Jan. 6, 2004 andreferences incorporated therein), red enhanced cerium doped yttriumaluminum garnet, a molecular composition different than theunderivatized cerium doped yttrium aluminum garnet is isolated withremoval of the reaction solvent. The red enhanced yttrium aluminumgarnet composition of matter is suspended in a mixture of a castingpolymer and a solvent and a film is sequestered within the sealed secondenclosure 111 of FIG. 2.

The amount of dyes or fluorescers specifically formulated into theexternal luminophoric medium, which may for example include a polymericmatrix or other matrix material in which the dyes and/or fluorescers aresoluble or dispersible, is not specifically limited, and suitableamount(s) of suitable material(s) for such purpose can be readilydetermined without undue experimentation, to provide good achromatic, orchromatic light emission (of virtually any tint or hue), as well as avirtually infinite series of chromaticity for all visible hues.

The amount of dyes or fluorescers specifically formulated into theluminophoric medium internal to the chamber or cavity, which may forexample include a ceramic non-luminescent dispersant in which theorganic dyes and/or fluorescers are adsorbed and or otherwisedispersible, is not specifically limited, and suitable amount(s) ofsuitable material(s) for such purpose can be readily determined withoutundue experimentation, to provide good achromatic, or chromatic lightemission (of virtually any tint or hue), as well as a virtually infiniteseries of chromaticity for all visible hues.

The concentrations of the fluorescers may suitably be determined by boththeir luminescence quantum yields and spectral distribution, as requiredto define a particular color by its respective chromaticity coordinates,as well as, in the case of radiative energy transfer (but not Forsterenergy transfer), the absorption extinction coefficients of theassociated fluorescer(s). Such fluorescers may for example be blue lightfluorescers used with a blue-emitting semiconductor-based LED die, orultraviolet light fluorescers used with a UV-emittingsemiconductor-based LED die. While the concentrations of the variousdyes may be suitably adjusted to realize the required colors, the rangeof dye concentrations typically will be between 10-3 to 10 mole percentfor each individual fluorescent component.

The light-emitting assemblies shown in FIGS. 1 and 2 and 3 may be madein any suitable size and dimensional character. In application todisplays, such light-emitting assemblies will generally be of a sizecommensurate with the size of fluorescent or incandescent lamps used insimilar displays.

Referring more specifically to FIG. 4, only the down-converting mediumis placed within a secondary enclosure and this arrangement issufficient to protect the down-converting medium from deleteriouselements. More specifically, a light emitting assembly may beconstructed according to the design of FIG. 3 and at the same timeadditional down-converting medium—as a luminescent element—may beprotected according to the design of FIG. 4.

The following method is sufficient to coat a ceramic phosphor onto theinner wall of the secondary enclosure:

1. An aqueous solution of polyvinyl alcohol (PVA) is made by adding 5grams of PVA powder to 200 ml of water. The mixture is heated to 85° C.with stirring for one hour, then cooled to room temperature, andrefrigerated at 2° C. overnight.

2. YAG:Ce (0.75 gram) having a particle size of from about 2-9 microns,is added to 1.5 ml of the above solution, and shaken for 5 minutes toform a phosphor slurry.

3. The slurry is applied with a micro syringe or an injection nozzle toinner wall of a secondary enclosure. The typical volume of the phosphorslurry applied to each die can be about 1.5 micro liters.

4. The secondary enclosure is baked in an oven at 130.degree. C. for 5minutes to polymerize the binder.

Another method that may be used to practice the claims of this presentinvention is using a nanophase binder system as described morecompletely elsewhere. (M.A. Johnson, et. al.; Canadian PatentApplication CA 2330941) The phosphor impregnated binders are coatedwithin the chamber of the present invention where the phosphors selectedneed not be limited to the luminophors identified by M.A. Johnson et.al. but where the binders identified therein are used to apply phosphorswhere the phosphors are selected from the embodiments presented in thispresent invention as disclosed herein.

Ceramic phosphors used in such a manner may also include those fromNemoto Chemie Co., Ltd.; Tokyo 167-0043, Japan: CaAl2O4:Eu2+,Nd3+(blueemitter with an emission maximum at 440 nm; excitation peak at 325 nm);SrAl14O25:Eu2+,Nd3+(blue-green emitter with an emission maximum at 490nm; excitation peak at 365 nm); SrAl2O4:Eu2+,Nd3+(green emitter with anemission maximum at 530 nm; excitation peak at 365 nm).

In one embodiment, the red, green and or blue luminophors when using anultraviolet LED die or 1) red and green or 2) red, green and yellow, or3) red, green yellow and blue, or 4) red, green blue, yellow and cyanluminophors are printed onto the surface of the protecting and enhancingenvelope using ink-jet printing where the image of colored luminescentinks is optimized to create the appearance of white light from allviewing angles and or all angle on which the light falls on to asurface. In one embodiment, the red, green and or blue luminophors whenusing an ultraviolet LED die or 1) red and green or 2) red, green andyellow, or 3) red, green yellow and blue, or 4) red, green blue, yellowand cyan luminophors are printed onto the surface of the protecting andenhancing envelope using ink-jet printing and where the enhancingenvelope is replaceable and interchangeable at will. In this case, forexample a white light LED lamp utilized in an automobile, the light willlast as long as the functioning of the LED die and the changes in colorover time can be immediately reversed by inserting a replacementenhancing envelope or chamber containing different and newer luminescentelements. The exemplary disclosed system, apparatus, and method mayinclude any suitable heat exchanger that transfers heat generated by onedevice to another (e.g., to the heat exchanger itself), where theinitially formed heat is dissipated away from the originating device andto external surroundings. For example, the exemplary disclosed system,apparatus, and method may include a passive heat exchanger (e.g., a heatsink).

The exemplary disclosed heat exchanger (e.g., heat sink or any othersuitable type of heat exchanger) may regulate the temperature of theoriginating device, by cooling, removing heat, and by subsequentlyheating (e.g., adding heat) to the external environment. This may be athermodynamic process, as thermal energy moves from a source of hightemperature to a reservoir of lower temperature. This process involvesthe second law of thermodynamics, which governs spontaneous processeswhen the entropy of the process increases.

The exemplary disclosed heat exchanger (e.g., heat sink) may be designedto maximize its surface area in contact not only with the device to becooled but also with the medium surrounding it and or the externalenvironment to which the heat is ultimately transferred. The exemplarydisclosed heat exchanger (e.g., heat sink) may include aluminum, copper,and/or any material that has a capacity to receive, and transport away,more heat from the originating device than said device can otherwisedissipate on its own (e.g., absent the heat sink). As additionalexamples of materials, the exemplary disclosed heat exchanger (e.g.,heat sink) may be made of glass, porous glass, and/or metal on glass.The heat sink may have internal channels, pores, enclosures or externalauxiliary accompaniments (i.e.; elements) that accelerate the rate andintegrated capacity (integrated over area or over time) for the transferof heat to the external surroundings, faster, and more completely inquantity, than the heat sink would otherwise be capable, absent saidinternal or external elements. Interior channels within the heat sinkmay be filled with nanofluids such as alumina (aluminum oxide orsapphire) dispersed within an aqueous dispersion.

The exemplary disclosed heat exchanger (e.g., heat sink) may transferthe heat it receives from the originating device to the externalsurroundings by increasing the surface area of the interface between theheat sink, the external auxiliary accompaniments and ultimately with theexternal surroundings. The exemplary disclosed heat exchanger (e.g.,heat sink) may provide for a suitable amount (e.g., a substantiallygreatest amount) of heat that can be transferred considering availablearea (e.g., area of a device including a white light source powered bylight-emitting diodes when integrated within an electrical circuit ofsuitable current and force).

The exemplary disclosed heat exchanger (e.g., heat sink) may be attachedto a device by any suitable technique, such as directly to alight-emitting diode die, to an enclosure that contains a light-emittingdiode die, as an internal element or an external accompaniment to anenclosure; as an internal element itself, or as an externalaccompaniment itself to an enclosure that contains an inner enclosurewithin its inner space or interior space (e.g., depending on whether theenclosure is an outer enclosure or an innermost secondary enclosure,respectively).

Attachment methods may include a metallized paste or adhesive orthermally conductive adhesive tape. Pressure may be used to attach aheat sink so that the space between the heat sink and the originatingdevice (or any other supplementary intermediary device) being cooled hassuitable (e.g., minimal) voids of space which may be thermallyinsulating. Alternatively, space or gaps, if properly placed, may beused to enhance a performance the exemplary disclosed heat exchanger(e.g., heat sink) its ability to regulate temperature.

The exemplary disclosed heat exchanger (e.g., heat sink) may bepositioned within an enclosure that also contains a gas and thelight-emitting diode die whose junction temperature is the temperaturethis invention seeks to regulate. Heat transfer in fluids such as gasmay occur by a process known as convection. Convection is realizedbecause of upward buoyant forces, themselves a consequence of thedifference in density between the lighter hotter part of the gas and thecooler, denser part of the gas. If the gas has multiple molecularcomponents, the buoyant forces may force a slight separation of thecomponents so that at every region of the inner space or interior space,as the case may be, would not have exactly the same proportion of gases.

Acting against the gravitational force, the buoyant force makes thehotter gas rise and the cooler gas fall. If there is a vent at the topof an operating assembly such as a lighting device, the hotter gasescapes. If there is a vent near the bottom of the assembly, externalgas refills the enclosure with cooler yet gas from the externalsurroundings. The exemplary disclosed heat exchanger (e.g., heat sink)may enhance the transfer of the heat from the originating device to thegas and to the walls of the enclosures. Thus, in at least some exemplaryembodiments, the buoyant forces power the energy conversionrepresentative of heat transfer. In at least some exemplary embodiments,the energy conversion comes at a cost as the convective currents areirreversible (and, spontaneous in natural convection); entropy isgenerated to some degree with irreversible thermodynamic processes; withentropy generation comes some inefficiencies and the conversion ofenergy into work and non-work components.

In at least some exemplary embodiments, the exchange of energy betweenthe exemplary disclosed heat exchanger's solid-state surface and the gasenvironment are the source of entropy generation. In at least someexemplary embodiments, the entropy so generated is powered by thethermal energy and the viscous flow and friction (between the convectivecurrent and the solid-state surface of the heat sink) that worksagainst, along with the gravitational force, the convective flow. Inthermodynamic processes, it may be appropriate to identify the forces,the energy and the power associated with wanted work and unwanted work.

The exemplary disclosed heat exchanger (e.g., heat sink) may beconstructed of many different machinable designs including a radial heatsink with a thermal profile and swirling forced convection flowtrajectories. In at least some exemplary embodiments, conduction andthermal radiation can be techniques by which a heat sink also transfersthe heat it receives from the originating device, the light-emittingdiode die in general and the diode junction more specifically, to theoutside surroundings, but convection is also a technique by which theheat may be transferred and the originating device, and or any suitableintervening device, may be cooled. In at least some exemplaryembodiments, convection is encouraged by the placement of a gas flowdevice or the convection can occur naturally if there is an exit throughwhich gas may go in one lateral direction. A combination of conduction,thermal radiation and natural convection may simultaneously take place.The positive implementation of one does not negatively impact the other.

The exemplary disclosed heat exchanger (e.g., heat sink) may providethat design circumstances and cooling, the taking away of heat, isaffected by each method and or any combination of methods. In at leastsome exemplary embodiments, thermal radiation provides its own maximumcooling effect when the heat sink emulates a blackbody radiator and assuch is suitably efficient when the surface absorbs substantially allthe heat spectrum so that the emission of the thermal radiation to theexternal environment, which carries the heat, in the form of a maximumof entropy at each frequency, is suitable (e.g., substantially maximal).

In at least some exemplary embodiments, it is also the case that theconvection of heat, from the heat sink to the external surroundings, issuitable (e.g., best) when the convection currents are such thatadditional entropy is not also increased. This increase in entropy maybe a challenge when using a heat sink and subsequent convection to takeaway heat from the originating device and subsequently the heat sink.For the exemplary disclosed heat exchanger (e.g., heat sink), a radialflow heat sink with fins may minimize the amount of additional entropycreated due to the convection currents when compared with other designs.In at least some exemplary embodiments, the greater the increase ofentropy because of a defined process, the more spontaneous andirreversible it is. On the other hand, the greater the difference inentropy between the final and initial states, the more heat isintroduced into the system even a system designed to take away heat, tocool.

The exemplary disclosed heat exchanger (e.g., heat sink) may includematerials of different composition that have different coefficients ofthermal expansion. The units for the coefficient of thermal expansionmay be inverse degrees Celsius but there is a dimensionless component,m/mo, which is the change in length, m, divided by mo, the originallength (i.e.; m/(mo C)). In at least some exemplary embodiments, foraluminum, copper, borosilicate glass and fused quartz, the change inlength for 10 millimeters (mm) after heating from 0 C to 100 C is 10.023mm, 10.017 mm, 10.004 mm and 10.00055 mm. In at least some exemplaryembodiments, epoxy resin when cured, on the other hand, has aproportionately high coefficient of thermal radiation when compared withglass or metals which may also be elements of the light-emittingassembly.

In at least some exemplary embodiments, when incorporating a heat sinkin the internal space or interior space of an enclosure, the ends of theheat sink, from which the heat transfers to the external surroundings,may be near the walls of the enclosure but not touching the enclosurewalls themselves. The closer the terminus of the heat sink is to thewalls of the enclosure, whether it be the inner enclosure or the outerenclosure, the greater the quantity and rate of heat transfer to theexternal surroundings may be.

In at least some exemplary embodiments, in between the terminus of theheat sink and the walls of the enclosure, is the matter which comprisesthe inner space or interior space of the exemplary disclosed enclosure,such as the gas disclosed in the instant invention. In at least someexemplary embodiments, the thermal energy, the heat transfer, then ispassed from the heat sink through the gas to the walls of the enclosureand ultimately to the reservoir known as the external surroundings. Tominimize the gap between the terminus of the heat sink and the wall ofthe enclosure, but to allow differential thermal expansion so as to nothave the elements that abut mechanically break due to expansion forcespowered by thermal energy, spacing of gaps in the millimeter range maybe provided (e.g., less than about 100 millimeter, for example with lessthan about 10 millimeters, or for example less than about 7.5millimeters). In at least some exemplary embodiments, the smaller thegap between the terminus of the heat sink and the walls of theenclosure, the greater the dependence of the gas' molecular weight,molecular diameter, and more importantly its kinetic diameter.

In at least some exemplary embodiments, for gases entrained within theenclosures of the instant invention, the kinetic diameters (in “pm’;picometers) are: Hydrogen (2), Helium (2), Neon (20), Argon (40),Krypton (84), Xenon (131); 289 pm, 260 pm, 275 pm, 340 pm, 360 pm, 396pm; respectively. The greater the kinetic diameter, the greater the gasviscosity and the more the viscosity works against the convectioncurrents involved to transfer heat (energy conversion) via convectionthrough the gas. For example, Helium may be used as the entrained gaswithin an optically-clear enclosure that contains the terminus of theheat sink within about 10 mm of the wall of the enclosure in which itcomprises.

Referring to FIG. 3, the exemplary disclosed heat exchanger such as aheat sink 705 is shown attached to the base of the substrate on whichthe GaN semiconductor has been grown. The heat sink may be attached tothe substrate using the attachment methods that enhance thermalconnectivity and as for example as described herein. The heat sink 705may or may not be co-terminus with the substrate to which it isattached. For example, the heat sink may extend beyond the edges of thesubstrate and any other layer that makes up the light-emitting diode dieso that the extension places the terminus of the heat sink near theinner wall of the optically-transmissive enclosure whose walls may formthe boundaries of an interior space. The heat sink 705 may receive heatfrom the junction that has been formed within the light-emitting diode,the heat sink being in thermal contact with the diode die andtransferring said heat through the gaseous region entrained within theinterior space. The gaseous region may comprise Noble gases, enhancinggases as hereinbefore described, gases with high thermal diffusivity, orgases with the least kinetic diameter yet inert as well. A suitable gasfrom the perspective of the kinetic diameter may be Helium (e.g., amonoatomic gas smaller in collisional area or volume than diatomichydrogen gas). The closer the terminus of the heat sink 705 is to theinner wall of the optically-transmissive enclosure, the greater thesuitability for Helium may be (e.g., a compared to Hydrogen).

As shown more fully in FIG. 3, there may be innermostoptically-transmissive enclosures, each of which may contain at leastone light-emitting diode die with a heat sink to generate the optimal ormaximal amount of lumens necessary for the proper use of the LED-basedlight bulb. The light bulb may have vents so that convection current candissipate the heat introduced into inner space of an outeroptically-transmissive enclosure that forms the boundaries of the lightbulb or light fixture. The heat so introduced in the preceding sentencemay be from a heat sink within the interior space of a secondary, inneroptically-transmissive enclosure whereby the heat sink may extendrelatively close to the inner walls of the inner optically-transmissiveenclosure that defines the interior space (e.g., and whereby the heat istransferred through the gas entrained within the interior space andthrough the walls of the inner enclosure and into the vented inner spaceof the enclosure that forms the light-bulb or light fixture). Theaforementioned innermost optically-transmissive enclosure(s) may bemounted onto a heat sink vertical post 702 that may also contain theelectrical leads to provides the power (the force at a suitable current)so that each light-emitting diode die may be within a closed-electricalcircuit. The vertical post acting as a heat sink, 702, is presentwhether or not the outer enclosure has a vent or not. With theappropriate vents, convection currents through the gas transport theheat, by buoyancy forces, vertically up the enclosure. Absent the ventsin the outer enclosures, the heat transfer relies on conduction andradiation through the gas and through the outer sealedoptically-transmissive enclosure to the surrounding reservoir ofatmospheric gas. In at least some exemplary embodiments when vents arenot present, the convection currents that ultimately displace the heatrise along the outside walls of the outer optically-transmissiveenclosure. The unwanted entropy generated along the outside walls ofenclosure are minimal (e.g., but is at a maximum, for that convectivecurrent some distance from the outer wall in a parabolic leading shapein the convective flow moving upwards vertically along, parallel to, theouter wall of the outermost optically-transmissive enclosure). In theabsence of vents, the walls of optically-transmissive outer enclosuremay be relatively more thermally conductive as compared to walls inwhich vents are present.

In at least some exemplary embodiments absent the vents, the outermostenclosure may be a sealed enclosure and the heat sink post 702 maycontain an external accompaniment 700 that may have fins perpendicularto the vertical alignment of the post 702. The transfer of heat throughthe gas may be greater when the number of fins promulgating from theexternal accompaniment is greater than one. The submount 701 may containat least one (e.g., a multiplicity of) light-emitting diode dies,arranged in a manner vertically upward to provide a suitable (e.g., themaximum amount) of light in some or all directions desired (e.g.,anywhere from 30 degrees to 360 degrees). In at least some exemplaryembodiments In which the outer enclosure includes facing a wall or aceiling, 180 degrees may be the angle for which the submounts 701 arealigned along the vertical post 702. There may be multiple LED submounts(e.g., and/or each submount may have a multiplicity of LED dies). Theexternal accompaniment 700 may be arranged along the heat sink 702 sothat there is suitable interference (e.g., minimally interfere) withtransmission of light. The fins associated with the externalaccompaniment 700 may be arranged relatively close to each other so thata channel is formed in the intervening space between fins arranged inparallel to each other. Depending on the size of the light bulb or lightfixture, the faces between two fins in parallel placement to eachother's face may be arranged so that there is about 10 millimeters,about 7.5 millimeters, or about 5 millimeters gap between the two faces.If more than two fins are so arranged, the gap between each of manyfaces may be at least about 10 millimeters, about 7.5 millimeters, orabout 5 millimeters. In at least some exemplary embodiments in thesealed enclosure that forms the outer boundary of the inner space, theterminus of the fins may be relatively far from the inner walls of theoutermost optically-transmissive enclosure as the heat will betransferred from the heat sink alongside the faces of the gap betweenfins and through the gas to the walls of the outermost sealed enclosure.In at least some exemplary embodiments, the buoyant force will flow in aparabolic leading edge at the halfway point between each face of thechannel between each fin until it reaches the terminus at which pointthe buoyant force will flow vertically, itself determined based on howthe light bulb is oriented in a light fixture. In at least someexemplary embodiments, the parabolic leading edge is where entropy ofthe convective current will be generated and along the interface betweenthe face of each fin and the heat flow, there will be minimal entropygenerated. In at least some exemplary embodiments because the outermostenclosure is sealed, there will be only a small amount of convectiveflow (e.g., and the larger the inner space, the greater the convectiveflow). In at least some exemplary embodiments if the inner space isextremely large, the convective flow will be maximal and the inner spacewill operate in a manner similar to the ambient external reservoir ofsimilar size. To avoid negatively impacting the amount of illuminancedelivered to the light bulb or fixture, the external accompaniment maybe positioned on the heat sink 702 so that it is near or nearest thewalls of the outer enclosure where little light is transmitted. By wayof example, radial external accompaniment 703 may include a multiplicityof fins having faces that are parallel to the conducting base of thelight bulb but extending so that their terminus is near the bottom ofthe outermost optically-transmissive enclosure and as close to the innerwall of the outermost optically-transmissive enclosure so that asuitable (e.g., minimal) gap is present. This gap may be no more thanabout 10 millimeters, about 7.5 millimeter, or about 5 millimeters. Inat least some exemplary embodiments, the heat will swirl from the radialexternal accompaniment through the gas to the wall of the outerenclosure.

In at least some exemplary embodiments and as illustrated in FIG. 4,more fully is shown a glass or metal heat sink suspended within acentral glass cylinder the boundaries of which forms the interior spacewithin the sealed innermost secondary enclosure withoptically-transmissive walls. The front and back space of the glasscylinder may be co-terminus with the solid cylindrical face of thecylindrical heat sink so that sealing the heat sink into the glass facesof the innermost secondary enclosure provides support keeping the heatsink in place. Also for example, the terminus of the heat sink, withrespect to the front face or the back face, or both, may extend beyondthe glass walls that form the seals of the cylindrical enclosure.

Heat generated by the Stokes shift of the fluorphors absorbed onto orcovalently attached to the interior wall of the glass,optically-transmissive, sealed, inner enclosure, which contains aninterior space filled with a gas may be transmitted through the gas tothe heat sink and subsequently out of the heat sink terminus exposed tothe outside environment. When the cylindrical inner enclosures aremultiple in number, they may be arranged to be in a parallel verticalplacement so that all the heat sink faces are aligned in a parallelplace ending at the same place within the outermost enclosure. In atleast some exemplary embodiments, these cylindrical enclosures withinwhose interior space is a gas and a cylindrical heat sink are convertersand are placed within the inner space of an outermost enclosure, itselfmade of epoxy, silicon or glass. If the cylindrical heat sink within theinterior space of the inner enclosure is glass, or phosphor infusedglass, then the sealing through the circular face of the walls end mayallow for a hermetic seal. If the cylindrical heat sink laid out as aplane is metal, then the seal may not be hermetic due to the differenceof thermal expansion of metal and glass at the orifical exit.

In at least some exemplary embodiments, the exemplary disclosed devicemay include at least one of a light emitting diode with a p-n junctionoperable to emit radiation when coupled with a power source, a pluralityof optically transmissive enclosures, and at least one outeroptically-transmissive enclosure the boundaries of which contain aninner space within which is a plurality of innermost, secondoptically-transmissive enclosure, the wall of which form the boundariesof an interior space in each second enclosure. Said interior space mayhave within each at least one said light-emitting diode. A heatexchanger may be disposed adjacent to the wall of the secondoptically-transmissive enclosure. A region of the inner space maycontain an atmospheric volume that is in thermal contact with theexterior walls of the at least one of the said second enclosures. Theatmospheric volume may be a vacuum with a vacuum pressure less than 501millibar and more than 0.005 millibars. The atmospheric volume maycontain a gas other than air with a pressure less than 2,001 millibarand more than 500 millibar, wherein the gas has a protecting orenhancing effect. The exemplary disclosed device may also include aluminescent element covalently attached to the outer wall of a secondaryenclosure. Said semiconductor light-emitting diodes may emit a primaryradiation. Said luminescent element may be radiatively excited by theprimary radiation so as to cause the luminescent element to emitsecondary radiation, wherein the luminescent element is exposed to agas. The exemplary disclosed device may include a luminophor coated ontothe exterior walls of a second enclosure, said walls including a glass,and said luminophor immersed within the inner space's atmosphericvolume. Said luminophor's emission spectrum may be variable based on thetemperature of the atmospheric volume it experiences. The gaseousenvironment may reversibly change during the operation of the devicesuch that the device acts as a sensor. Heat may be removed byconduction, convection, or by thermal radiation via the gas or vacuum,through the wall of the second optically-transmissive enclosure via theheat exchanger to the outside environment. The heat exchanger may be aheat sink disposed within the inner space. The heat exchanger may be aheat sink disposed within the interior space.

In at least some exemplary embodiments, the exemplary disclosed devicemay include at least one single-die semiconductor light-emitting diodewith a p-n junction including an optically-transmissive enclosure theboundaries of which form an inner space where in the inner space has aregion of a gaseous environment other than air, and a secondaryoptically-transmissive enclosure within the inner space of the outerenclosure the boundaries of which form an interior space wherein theinterior space has a region of a gaseous environment other than air,different than the gaseous environment in the inner space. A heatexchanger may be disposed adjacent to the boundaries of the secondaryoptically-transmissive enclosure. The at least one light-emitting diodeto emit light when energized with an electrical current may be in theinner space of said optically-transmissive enclosure. The exemplarydisclosed device may include a fluorescent, a phosphorescent, athermo-luminescence or an electroluminescent material coated on theexterior walls of the second enclosure. The gas in the inner space maybe ammonia, nitrogen, argon, krypton or xenon or any combinationthereof. The gas in the interior space may contain argon, krypton orxenon or any combination thereof. The heat exchanger may be a heat sinkdisposed within the inner space. The heat exchanger may be a heat sinkdisposed within the interior space.

In at least some exemplary embodiments, the exemplary disclosed devicemay include at least one of a single-die, a two-lead GaN semiconductorlight-emitting diode die capable of emitting radiation said diode thedonor, and a recipient luminophoric element for convertingnon-radiatively energy transferred from the donor to the luminophoricelement. The ground-state of the acceptor may be capable of reducing theexcited state lifetime of the donor. The two-lead diode die may bewithin the interior space of a secondary optically-transmissiveenclosure with a layer of luminescent element, said element an acceptor.The same or different luminescent element may be in the interior spaceof each of a plurality of different secondary optically-transmissiveenclosures, said element a converter. The interior space of both thesecondary optically-transmissive enclosure containing a light emittingdiode die and the secondary optically-transmissive enclosures containingluminescent element may include a region of the same or different Nobleor otherwise inert gas. All of the secondary enclosures may be withinthe inner space of an outer optically-transmissive enclosure. A heatexchanger may be disposed in the inner space or the interior space. Theluminescent material that is an acceptor may include cerium dopedyttrium aluminum garnet. The converter may include an optically active,chiral luminescent material. Heat may be removed by conduction,convection, or by thermal radiation through a wall of the secondaryoptically-transmissive enclosure via the heat exchanger to the outsideenvironment.

In one embodiment, and referring to FIG. 1, again, as hereinbeforedisclosed, an achromatic or chromatic or infra-red light emitting diodeassembly may function to down convert the light output from face 18 ofLED 13 or reflecting off of surface 14 on which LED 13 rests toachromatic, chromatic, or infra-red light. With respect to FIG. 2,again, the surface 14 may be one which may be designed to have lightreflect off of the surface and reorient the light through thesemiconductor itself, for example if the substrate itself is notmirrored or is otherwise transparent. For example a contact, such as then-contact, may be purposely increased in size and reflective of light soas to either direct the light in one direction and or to recycle thephotons for another chance of exiting the assembly or another chance ateffecting down-conversion. However, with multiple passes, primaryradiation's multitude of different states may co-exist, therebythermodynamically decreasing the efficiency of the overall process.Hence, in an embodiment whereby directional light may not be desired,obtained through transparent substrates, supports and leads, as well asto avoid thermodynamic inefficiencies due to photon recycling (XiaoyunGuo, John W. Graff, E. Fred Schubert; “Photon Recycling SemiconductorLight Emitting Diode”; in “Light-Emitting Diodes: Research,Manufacturing, and Applications IV”; Proceedings of SPIE—TheInternational Society for Optical Engineering; Eds. H. Walter Yao, IanT. Ferguson, E. Fred Schubert; 26-27 Jan. 2000 San Jose, Calif.), it maybe desirous that the surface of the support 14 does not have primary orsecondary radiation reflect off of the support.

A technique by which this may be accomplished may be by creating anelastomeric ribbon into which are embedded a plurality of light emittingdiode dies with their leads, said leads making a connection with anexternal power supply, and whereby the elastomeric ribbon may providethe structural support suitable to keep the plurality of LEDs orientedin some desired manner so that a suitable (e.g., maximum)multi-directional (e.g., but not omni-directional) radiation is emittedthrough the elastomeric ribbon. FIG. 5 shows how the elastomeric ribbonmay be oriented in a light bulb device. FIG. 6 shows a detail of one ofmany possible geometric structures for elastomeric ribbons used in theinstant invention.

In at least some exemplary embodiments and as illustrated in FIGS. 5 and6, elements of the exemplary disclosed invention may include:

FIG. 5

1. filament-like LED populated enclosure 7031

2. filament-like LED populated enclosure 7041

3. optically transmissive outermost enclosure 7001

4. demarcation point 7072

5. optically transparent inner space 7051

6. filament-like LED populated enclosure 7011

7. Inner post 7021

8. inner space 7051

9. base to optically transmissive outermost enclosure 7061

10. external contact 7071

FIG. 6

1. elastomeric ribbon enclosure 7200

2. light-emitting diode array 7101

3. elastomeric enclosure component 7091

4. elastomeric enclosure component 7081

5. light-emitting diode dies 7102

In at least some exemplary embodiments and as illustrated in FIG. 6, theexemplary disclosed invention may include LEDs with a p-n junction,comprising a transparent substrate and disposed (e.g., imposed) upon atransparent plate or board, a plurality of which may be positionedwithin an inner enclosure (e.g., the elastomeric ribbon enclosure 7200),said enclosure comprising an atmospheric volume (a volume of spacecomprising an atmosphere) so encased within the inner walls of theenclosure, 7200. Elastomeric ribbon enclosure 7200 may be formed frommaterial that is the same as or similar to optically transmissiveoutermost enclosure 7001. The luminescent element that down-convertslight may be impregnated within the elastomeric member (e.g., elongatedelastomeric member such as elastomeric ribbon 7200) so that the p-njunction of a plurality of diode dies, and the luminescent element, maybe sequestered within the same enclosure 7200. There may be a pluralityof light-emitting diodes some or all of which in combination may providethe primary radiation which may be down-converted and or scattered sothat the combination appears achromatic.

The phosphor (e.g., one that emits from the singlet excited state) maybe impregnated into the elastomeric ribbon enclosure 7200 so that theindividual light-emitting diodes may either be not visible or theoutlines of same may be visible but the boundaries of which may not beotherwise discernible. If so desired, so that the individuallight-emitting diodes are discernible, the phosphor may be incorporatedas a layer on the light emitting diode die itself.

The elastomeric ribbon may form an enclosure (e.g., an innermostenclosure) that may be a flat or tubular narrow and continuous materialof some length so that the appearance of same over its length may havethe same far-away appearance as a closely woven fabric (e.g., of silk orrayon) used for example for trimmings or knitting. In one embodiment theelastomeric ribbon may be flat as it encases an array of flatlight-emitting diode dies and the outer boundary of the elastomer maypurposely seek to emulate the shape of the fully encased (e.g., enclosedin, covering or containing the structure or layer, or enveloped) diodedies themselves. The exemplary disclosed enclosure may include an areathat may be substantially fully or partially sealed off with anartificial or natural barrier.

The exemplary disclosed ribbon, when populated with a plurality ofpowered and emitting diodes dies, may give the appearance of a filament,which may be a wire-like or thread-like material which emits radiationincluding luminescence (e.g., the likeness being one judged by a casualhuman observer some distance from the device which contains the ribbonwithin its inner space). In an incandescent bulb with a transparentglass outermost enclosure, the filament may be coiled. The part of thefilament facing the external transparent glass may appear brighter thanthe part of the filament facing away from the external glass, therebyproviding a discontinuity in brightness along the filament length asmeasured from a plane above the filament. In the same manner, a humanobserver looking at a plane above the filament ribbon may seediscontinuities (though the ribbon may not be coiled) because of thedistance between light-emitting diode dies in a fully transparentelastomeric ribbon enclosure, 7200.

By way of example, FIG. 5 shows more clearly an outer enclosure (e.g.,an optically transmissive outermost enclosure 7001) connected to a base7061, the combination of which may form the boundary of the lightingdevice (e.g., a light bulb) and encasing an inner space 7051, itselfoptically transmissive. Optically transmissive outermost enclosure 7001may be formed from any suitable material such as glass and/or any othersuitable optically transmissive material. For certain desired aestheticbenefits, the optically transmissive inner space 7051 and the opticallytransmissive enclosure 7200 may both be clear (e.g., without scatteringof light) or not clear (e.g., with scattering of light). In theexemplary disclosed invention, light may be emitted from a Lambertiansurface.

Lambertian reflectance may provide a suitable diffusely reflectingsurface. The apparent brightness of a Lambertian surface to an observermay be the same regardless of the observer's angle of view. Theluminance from a Lambertain surface may be isotropic. In the instantinvention, if the optically transmissive enclosure is less than asuitable (e.g., ideal) Lambertian surface, as the situation may be withan optically-transparent enclosure, then the luminance at any one pointon the external surface of the lamp may be different than another pointarbitrarily selected. The same may occur for the illuminance (e.g., thelight from the lamp falling onto a surface) such as a reading surface, abook, or a machine to be operated. An example of lighting without aLambertian surface may be incandescent bulbs with a tungsten filament ina clear glass enclosure. Such bulbs may provide non-uniform lighting andwhen the glass may be subsequently frosted (e.g., the incandescent lightmay emit from a near Lambertian surface).

When the elastomeric ribbon of the instant invention may be of a clearresin after curing (e.g., and without phosphor impregnated therein), thediode dies 7102 may appear as bright spots along the LED array withintervening spaces of dark spots (e.g., the bright ones providing thecolor or the wavelength emitted from the p-n junction of the die). Thegreater the number of diode dies comprising the LED array within anelastomeric ribbon may be, then the longer the ribbon or the closer thebright spots may appear to a human observer at least some distance awayfrom the optically-transmissive enclosure. This discontinuity due tospacing of emitting diode dies may provide an image similar to theaforementioned discontinuity of brightness from a coiled incandescentfilament.

Referring to FIG. 6, the exemplary disclosed invention of a plurality ofLED dies (7102) disposed within a plurality of elastomeric resinenclosures (e.g., some or all disposed or situated within an outer-mostoptically-transmissive enclosure 7001) may demonstrate that the ribbon7200 may provide emission of light from both the top of the diode dieand (e.g., if mirrorless or otherwise with a transparent diode diesubstrate) from the bottom of the diode die. The inner space 7051, whichmay surround the plurality of elastomeric ribbon enclosures (7081 and7091), may comprise an atmospheric volume that may be in thermal contactwith the elastomeric ribbon enclosure. The atmospheric volume in theinstant invention may protect the elastomeric ribbon enclosure if thegas is one that may prevent oxidation, hydrolysis, melting, brittleness,and other techniques of photon-induced degradation. The elastomericribbon enclosure shown as 7200 in FIG. 6 may be mounted in a light bulbas shown in FIG. 5, whereby the elastomeric ribbons are for exampleshown as 7031, 7041 and 7011. The elastomeric ribbon 7011 and 7031 maybe vertically aligned as suitable for an orientation of a light bulbwhen in use. The elastomeric ribbon 7041 may be horizontally aligned. Inaddition to including both vertically-aligned and horizontally-alignedelastomeric ribbons mounted in any one lighting device, a singleorientation may be utilized (e.g., more economically utitlized) in anyone lighting device. As shown in FIG. 6, 7200, elastomeric ribbons 7011,7031, and 7041 may be linear or of any suitable shape or direction sothat they can be mounted in a manner for example as shown in FIG. 5.

For example if base 7071 in FIG. 5 is considered as a “south-facing”face, and the demarcation point 7072 (e.g., one-hundred and eightydegrees away and on the external face of the optically transmissiveenclosure) as a “north-facing” face, then whether the non-Lambertianemission from the bulb principally emits to the south and the north orto the east and the west may depend on how the exemplary disclosedelastomeric ribbons are arranged and secured to an inner post 7021.

Any suitable number of ribbons may be used, which may have any suitableshape. For example, FIG. 6 shows a ribbon enclosure 7200 with threedifferent components (e.g., one or more elastomeric enclosure components7091 and elastomeric enclosure components 7081). Each component may beof variable length with the components being of different or the samelengths as each other. An elastomeric ribbon enclosure may be comprisedof one elastomeric enclosure component or a plurality of elastomericenclosure components.

For example FIG. 6 illustrates that within each component there may befour diode dies (7102) in one specific array (7101). Also for example, anumber of dies in any one specific array may be the same or differentthan the number of diodes dies in other specific arrays that comprise anindividual component.

For example there may be a single component within which there may be anLED array of as many diode dies as suitable to provide a desiredluminance and illuminance. As a number of diode dies that are assembledwithin an elastomeric enclosure component increases, the heat that isgenerated at the p-n junction and the energy difference (e.g., if any)between the emission wavelengths of the phosphor and the absorptionwavelengths of the phosphor (e.g., the Stokes shift) may be greater(e.g. involving an implementation whereby the phosphor is impregnatedwithin the elastomeric resin that comprises the elastomeric ribbonenclosure).

In an exemplary embodiment of the instant invention, the elastomericribbon enclosure 7200 comprising components 7091 and 7081 may bearranged vertically to provide suitable (e.g., maximal) emission throughthe east-facing face and the west-facing face (e.g., shown asfilament-like LED populated enclosure 7011 and filament-like LEDpopulated 7031 in FIG. 5).

In another exemplary embodiment, the elastomeric ribbon enclosure 7200may be arranged horizontally (e.g., shown as filament-like LED populatedenclosure 7041) to provide maximal brilliance from the north-facing faceand light reflected off the inner face of external contact 7071 (as 7071itself may be placed with an opaque receptacle for the screw-in base7061).

The diode dies that make up each LED array may be mounted on atransparent substrate or board backing to the LED array 7101 that maycontain electrical connectors, which may be transparent or opaque, tothe contacts of the p- and for the n-layers of the LED dies. The purposeof the backing may be to provide some rigidity to the elastomericenclosure components so that they do not expand too greatly when anelectrical current is supplied by an external power source to initiateelectron-hole recombination and light emission. An unwanted expansion(e.g., unwanted if too great) may be a result of the aforementioned heatgenerated as a consequence of underlying inefficiencies that generateheat. Elastomeric enclosure components 7081 and 7091 may differ inarrangement in that leads to the power source may exit the elastomericenclosure components 7091 in order to bring in an electrical force ofsuitable energy to power the diode dies. The leads may exit through anopen face end portion (e.g., terminus) of the elastomeric enclosurecomponent 7091 or the terminus may be sealed around the leads exitingthe component so that the terminus of the elastomeric ribbon may not beopen to the atmospheric volume comprising the inner space 7051.

In at least some exemplary embodiments, the terminus of component 7091may be open and there may be a channel of atmospheric volume separatingthe inner walls of the elastomeric ribbon enclosure and the diode dies7102 mounted on a board or substrate. In at least some exemplaryembodiments, the terminus of components 7091 may be closed, sealedaround the leads exiting the components, and there may be a channel ofatmospheric volume separating the inner walls of the elastomeric ribbonsand the diode dies. For example, a gas of the atmospheric volume (e.g.,a gas for example that may be similar to the exemplary disclosed gasesdescribed herein) may be disposed in a channel disposed between an innersurface of a wall forming the inner enclosure (e.g., the elastomericribbon enclosure) and the plurality of lighting elements (e.g., thediode dies) embedded in the elastomeric ribbon.

When the terminus is open, the atmospheric volume of the interior spaceencased by the elastomeric ribbon 7200 may include the same gascontained within the atmospheric volume of the inner space 7051. Whenthe terminus is closed, the atmospheric volume of the interior space maybe the same or different than the gas of the atmospheric volume withinthe inner space 7051.

In at least some exemplary embodiments, the channel of atmosphericvolume separating the inner walls of the elastomeric ribbon and thediode die may remain and the same elastomer may be in intimate contactwith the board or substrate onto which the diode dies may be mounted. Inanother exemplary embodiment, there may be a channel of atmosphericvolume separating the board or substrate on which the diode dies aremounted and the inner walls of the elastomeric ribbon and thatatmospheric volume of the interior space may be of a gas that may be thesame as or different than that which comprises the inner space (e.g.,controlled by whether the terminus is open or closed faced). In anotherexemplary embodiment, the elastomeric ribbon may be in intimate contactwith both the diode die and the board or substrate on which the die ismounted as well as the leads emanating from the array and connected toan external power source.

In at least some exemplary embodiments and as illustrated in FIG. 6showing elastomeric ribbon assembly 7200, the channels of atmosphericvolume may comprise an interior space within the inner enclosure 7200and a gas that transports heat away from the diode die and theelastomeric ribbon (e.g., as both the p-n junction, the phosphors inwhich a Stokes shift is exacted, may generate unwanted heat) and theheat may be transported to the atmospheric volume of the inner spacethrough the terminus of each component 7091 by: a) convection andconduction to the walls of the outer optically-transmissive enclosure7001 and ultimately to the external environment and/or b) thermalradiation through the walls of the optically-transmissive outerenclosure 7001. When the gas exits the open-faced terminus from withinthe elastomeric ribbon assembly, located for example as hereinbeforedescribed at the ends of components 7091, to the inner space 7051, thisprocess may parallel an adiabatic expansion of a gas provided the innerspace 7051 is greater (e.g., much greater) than the interior spacewithin the elastomeric ribbon 7200. For example as shown in FIGS. 7 and8, a volume of the inner space (e.g., each designated as 7051) fordifferent shapes of the outermost optically-transmissive enclosures maybe greater (e.g., significantly greater) than the volume of the interiorspace, for example formed by the boundaries of the inner secondaryenclosure 7200. Hence for example, the inner space may be considered theexternal environment into which the adiabatic expansion is taking place.For example for an adiabatic expansion of an ideal gas, the gas performswork (e.g., the expansion) and the temperature drops (e.g., when suchexpansion is performed in an system insulated from the externalsurroundings). Similarly for example, for a photon gas representingthermal radiation emitting from the channels, the adiabatic expansion ofthe photon gas obtains its energy, so as to perform work, from theinternal thermodynamic energy of the photon gas, thereby reducing thetemperature of the photon gas.

For example if the rate at which heat is generated (and the localtemperature) is increased in the channels, as a consequence ofinefficiencies in radical ion recombination (p-n recombination) at thep-n junction, and the secondary luminescence at the site of the Stokesshift is equal to the rate at which the temperature is lowered byadiabatic free expansion of gas exiting the open-faced terminus of thecomponents 7091, then the temperature of the overall device (e.g., thebulb) will not increase. On the other hand for example, if such a steadystate is not obtained, then the temperature of the atmospheric volumecomprising the inner space 7051 will increase, but not as high as wouldbe the case absent the instant invention. Further, the inner space maycontain a gas, the same as which comprises the atmospheric volume of theinterior space, when the terminus of 7091 is open-faced (e.g., that isthermally conductive and transports thermal energy to the walls of theoptically-transmissive outer enclosure 7001). For example if the wallsof the optically-transmissive outer enclosure 7001 is porous, then thegas that is in thermal contact with the elastomeric ribbon and/or thep-n junction may transport heat through the walls of the outer enclosure7001.

Porous enclosures may be made from porous Vycor glass or porousplastics, the pores being created by hydrofluoric acid and laserablation, respectively. The pores in porous Vycor glass may be 4nanometers, which may be considerably smaller than the wavelength ofradiation emitted by the p-n junction or that may be generated at thesite of a Stokes shift. While the porous Vycor glass may be translucentand may be observed as transparent as a function of humidity, theoptically transmissive outer enclosure 7001 made of porous Vycor glassmay experience light-scattering of the Rayleigh-type in radiation thatis visible. Porous polyethylene having pores in the hundreds of micronsmay also be used.

For diode dies mounted on transparent substrates or transparent boardsand within a transparent elastomeric ribbon enclosure, generally morecurrent may be used to power the p-n junction in order to obtain aspecific luminance at the surface of the optically-transmissiveenclosure, thereby generating more heat per surface photon measured.Consequently, the elastomeric ribbon enclosure (e.g., regardless ofwhether there is an opens-faced terminus or a cased-face terminus) maybe subjected to more heat than would otherwise be the case. Theincreased heat may lead to a shortening of the lighting device'soperational lifetime due to the aforementioned degradationpossibilities. It may be advantageous that the thermally connected gasmay also be one that reduces the oxidation not only of the luminophor orphosphor as previously noted but also that protects the elastomericribbon from such oxidation.

FIG. 5 illustrates a lighting device (e.g., a light bulb) with a screwbase. Any other suitable base may also be used. Two contact wires mayconnect the LED array, each within either 7041 or 7031 or 7011, to thebase of the light bulb, where an electrical voltage from an externalpower supply (e.g., when connected) may provide energy to the diodeswithin the aforementioned elastomeric ribbons. The contact wires may besoldered to the base metal at two different points on the base in orderto keep them affixed to the base metal.

In at least some exemplary embodiments, the exemplary disclosedapparatus may include an outer enclosure enclosing a first gas in afirst space, an inner enclosure disposed in the first space of the outerenclosure, at least one elongated elastomeric member disposed in theinner enclosure, and a plurality of lighting elements embedded in the atleast one elongated elastomeric member. The at least one elongatedelastomeric member may be an elastomeric ribbon. The inner enclosure mayenclose a second gas in a second space in which the at least oneelongated elastomeric member is disposed. The first gas may be the samegas as the second gas. The inner enclosure may include at least oneopen-faced end portion so that the inner enclosure fluidly communicateswith the first gas disposed in the first space. The first gas may bedisposed in a channel disposed between an inner surface of a wallforming the inner enclosure and the plurality of lighting elementsembedded in the at least one elongated elastomeric member. The pluralityof lighting elements may include a plurality of light emitting diodedies with a p-n junction. The at least one elongated elastomeric membermay include a transparent substrate disposed on a transparent plate orboard. The outer enclosure and the inner enclosure may be formed fromthe same material. The inner enclosure may be tubular. The plurality oflighting elements may be a plurality of light emitting diode dies. Theplurality of light emitting diode dies may be embedded with leads in theat least one elongated elastomeric member. The at least one elongatedelastomeric member may include a plurality of elongated elastomericmembers that are vertically aligned or horizontally aligned in the outerenclosure.

In at least some exemplary embodiments, the exemplary disclosed methodmay include enclosing a first gas in a first space using an outerenclosure, disposing an inner enclosure in the first space of the outerenclosure, disposing at least one elongated elastomeric member in theinner enclosure, and embedding a plurality of lighting elements in theat least one elongated elastomeric member. The first gas may be inthermal contact with the at least one elongated elastomeric member. Theexemplary disclosed method may further include transferring heat via thefirst gas from the plurality of lighting elements embedded in the atleast one elongated elastomeric member through a porous wall of theouter enclosure.

In at least some exemplary embodiments, the exemplary disclosedapparatus may include an outer enclosure enclosing a first gas in afirst space, an inner enclosure disposed in the first space of the outerenclosure, at least one elastomeric ribbon disposed in the innerenclosure, and a plurality of light emitting diode dies embedded in theat least one elastomeric ribbon. The outer enclosure may be transparentglass of an incandescent light bulb. The outer enclosure may be formedfrom porous Vycor glass or porous polyethylene. The at least oneelastomeric ribbon may be formed from elastomeric resin material.

Further, while the invention has been described primarily herein inreference to the generation of white light, it will be apparent that thescope of the invention is not thus limited, but rather extends to andencompasses the production of light of other colors than mixed whitelight, utilizing solid state primary radiation emitters, anddown-converting luminophoric media.

Thus, while the invention has been described with reference to variousillustrative embodiments, features, aspects, and modifications, it willbe apparent that the invention may be widely varied in its constructionand mode of operation, within the spirit and scope of the invention ashereinafter claimed.

What is claimed is:
 1. A microelectronic device, comprising: an outerenclosure enclosing a first gas in a first space; an inner enclosuredisposed in the first space of the outer enclosure; at least oneelongated elastomeric member disposed in the inner enclosure; and aplurality of lighting elements embedded in the at least one elongatedelastomeric member.
 2. The microelectronic device of claim 1, whereinthe at least one elongated elastomeric member is an elastomeric ribbon.3. The microelectronic device of claim 1, wherein the inner enclosureencloses a second gas in a second space in which the at least oneelongated elastomeric member is disposed.
 4. The microelectronic deviceof claim 3, wherein the first gas is the same gas as the second gas. 5.The microelectronic device of claim 1, wherein the inner enclosureincludes at least one open-faced end portion so that the inner enclosurefluidly communicates with the first gas disposed in the first space. 6.The microelectronic device of claim 5, wherein the first gas is disposedin a channel disposed between an inner surface of a wall forming theinner enclosure and the plurality of lighting elements embedded in theat least one elongated elastomeric member.
 7. The microelectronic deviceof claim 1, wherein the plurality of lighting elements include aplurality of light emitting diode dies with a p-n junction.
 8. Themicroelectronic device of claim 1, wherein the at least one elongatedelastomeric member includes a transparent substrate disposed on atransparent plate or board.
 9. The microelectronic device of claim 1,wherein the outer enclosure and the inner enclosure are formed from thesame material.
 10. The microelectronic device of claim 1, wherein theinner enclosure is tubular.
 11. The microelectronic device of claim 1,wherein the plurality of lighting elements are a plurality of lightemitting diode dies.
 12. The microelectronic device of claim 11, whereinthe plurality of light emitting diode dies are embedded with leads inthe at least one elongated elastomeric member.
 13. The microelectronicdevice of claim 1, wherein the at least one elongated elastomeric memberincludes a plurality of elongated elastomeric members that arevertically aligned or horizontally aligned in the outer enclosure.
 14. Amethod, comprising: enclosing a first gas in a first space using anouter enclosure; disposing an inner enclosure in the first space of theouter enclosure; disposing at least one elongated elastomeric member inthe inner enclosure; and embedding a plurality of lighting elements inthe at least one elongated elastomeric member.
 15. The method of claim14, wherein the first gas is in thermal contact with the at least oneelongated elastomeric member.
 16. The method of claim 15, furthercomprising transferring heat via the first gas from the plurality oflighting elements embedded in the at least one elongated elastomericmember through a porous wall of the outer enclosure.
 17. Amicroelectronic device, comprising: an outer enclosure enclosing a firstgas in a first space; an inner enclosure disposed in the first space ofthe outer enclosure; at least one elastomeric ribbon disposed in theinner enclosure; and a plurality of light emitting diode dies embeddedin the at least one elastomeric ribbon.
 18. The microelectronic deviceof claim 17, wherein the outer enclosure is transparent glass of anincandescent light bulb.
 19. The microelectronic device of claim 17,wherein the outer enclosure is formed from porous Vycor glass or porouspolyethylene.
 20. The microelectronic device of claim 17, wherein the atleast one elastomeric ribbon is formed from elastomeric resin material.